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General Procedures|Removal and Installation > < Diagnosis and Testing|Engine

S-MAX.Galaxy 2006.5 (03.2006-)

Engine - 2.0L Duratec-HE (MI4) - Valve Clearance Adjustment S-MAX/Galaxy 2006.5 (03/2006-)
General Procedures

Special Tool(s)
303-376B
Alignment Plate, Camshaft

303-499
Socket, Spark Plug

303-748
Locking Tool, Crankshaft
Materials
Name
Specification
Adhesive - Loctite 243
WSK-M2G349-A7
Hypoid Gear Oil
SQM-2C9002-AA
Silicone Sealant
WSE-M4G323-A4

  1. NOTE:
    NOTE:The gasket is to be reused unless damaged.

  1. Special Tool(s): 303-499

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until each piston is at top dead center (TDC) and measure the valve clearance(s), using a suitable set of feeler gauges.
  1. Note down each cylinder number and the valve clearance(s) measured.
  1. Compare the measured valve clearance(s) with the specifications.
    Refer to: Specifications (303-01A Engine - 2.0L Duratec-HE (MI4), Specifications).
  1. NOTE:
    NOTE:Only carry out the following steps when the valve clearance(s) require adjustment.

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until piston No. one is approximately 45 degrees before top dead center (TDC).

  1.  
    1. Punch 2 mm
    1. Open ended wrench
    1. Bolt M6 x 25 mm

  1. CAUTION:
    CAUTION:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

  1. CAUTION:
    CAUTION:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
    Loosen the intake camshaft sprocket retaining bolt by 5 turns.

  1. NOTE:
    NOTE:Note the position of the bearings.
  1.  
    • Remove the valve tappet and read the thickness from the underside.
    • The number on the valve tappet is the valve tappet thickness, however only the decimal places are marked (for example .650 = 3.650).
  1. Calculate the valve tappet thickness required (thickness of the currently installed tappet + the measured valve clearance - the required valve clearance).
  1. Install the correct valve tappet.

  1. CAUTION:
    CAUTION:Make sure that the camshafts and camshaft bearing caps are installed in their original locations.
    Coat the camshaft bearing caps with oil.
    Material: Hypoid Gear Oil
  1. Install the camshafts approximately at valve overlap position cylinder No. 4.
    Torque:
    Stage 1:
    7 Nm
    Stage 2:
    16 Nm

  1. NOTE:
    NOTE:Only tighten the bolt finger tight at this stage.
    NOTE:
    NOTE:Make sure that the camshaft sprockets can rotate on the camshafts.

  1. Install the special tool.
    Special Tool(s): 303-376B

  1.  
    • Bolt M6 x 25 mm

  1. Install the special tool.

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until it contacts the special tool.

  1. CAUTION:
    CAUTION:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
    Torque: 72 Nm

  1. Remove the special tool.
    Special Tool(s): 303-376B

  1. Remove the special tool.
    Special Tool(s): 303-748

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft one and three quarters until piston No. 1 is approximately 45 degrees before top dead center (TDC).

  1. Install the special tool.
    Special Tool(s): 303-748

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until it contacts the special tool.

  1. NOTE:
    NOTE:Only tighten the bolt finger tight at this stage.
    NOTE:
    NOTE:The bolt can only be installed if the valve timing is correct.
    • Bolt M6 x 18 mm

  1. NOTE:
    NOTE:The special tool can only be installed if the valve timing is correct.
    Install the special tool.
    Special Tool(s): 303-376B

  1. Remove the special tool.
    Special Tool(s): 303-376B

  1. Remove the special tool.
    Special Tool(s): 303-748

  1. Torque: 20 Nm

  1.  
    1. Material: Adhesive - Loctite 243
      Torque: 10 Nm
    1. Material: Adhesive - Loctite 243
      Torque: 12 Nm
  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until each piston is at (TDC) and measure the valve clearance(s).
  1. Repeat the procedure as necessary until all valve clearances are within the specified tolerance.

  1. Apply a small bead of sealant to the areas indicated.
    Material: Silicone Sealant

  1. Torque: 10 Nm

  1. Torque: 10 Nm

  1. Torque: 10 Nm

General Procedures|Removal and Installation > < Diagnosis and Testing|Engine