ford Workshop Repair Guides

Ford S-MAXGalaxy Workshop Service and Auto Repair Manuals

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S-MAX Galaxy: Engine Removal, Disassembly, Assembly

Engine - 2.3L Duratec-HE (MI4) - Engine S-MAX/Galaxy 2006.5 (03/2006-)

Assembly

Special Tool(s)
205-072
Universal Flange Holding Wrench

205-072-01
Adapter for 205-072

205-072-02
Adapter for 205-072

303-376B
Alignment Plate, Camshaft

303-509
Remover, Vibration Damper Hub

303-699
Wrench, Oil Filter

303-748
Locking Tool, Crankshaft
Materials
Name
Specification
Hypoid Gear Oil
SQM-2C9002-AA
Silicone Sealant
WSE-M4G323-A4
  1. NOTE:
    NOTE:New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after installation.
    Torque: 10 Nm

  1. Torque:
    Stage 1:
    10 Nm
    Stage 2:
    23 Nm

  1. CAUTION:
    CAUTION:Make sure that a new friction washer is installed.

  1.  
    1. Torque: 10 Nm
    1. Special Tool(s): 205-072, 205-072-01
      Torque: 25 Nm

  1.  
    • Apply sealant to the oil pan (bead diameter: 3 mm).
      Material: Silicone Sealant
    • Torque: 25 Nm

  1. Special Tool(s): 303-699
    Torque: 17 Nm

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Turn the crankshaft until no. 1 piston is at about 45° before TDC.

  1. CAUTION:
    CAUTION:Make sure that new bolts are installed.
    Torque:
    Stage 1:
    5 Nm
    Stage 2:
    15 Nm
    Stage 3:
    45 Nm
    Stage 4:
    90°
    Stage 5:
    90°

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

  1. Torque: 10 Nm

  1. Torque: 10 Nm

  1. NOTE:
    NOTE:The camshaft sprocket bolt must not be tightened at this stage.
    NOTE:
    NOTE:Make sure that the camshaft sprocket can rotate on the camshaft.

  1. CAUTION:
    CAUTION:Counterhold the camshaft at the hexagon with a wrench to prevent the camshaft from rotating.
    Torque: 72 Nm

  1. Apply sealant to the engine front cover (bead diameter: 3 mm).
    Material: Silicone Sealant

  1. Torque:
    1-8 10 Nm
    9 48 Nm
    10-19 10 Nm
    20-22 48 Nm

  1. CAUTION:
    CAUTION:Make sure that a new friction washer is installed.

  1. Special Tool(s): 303-509

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

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Turn the crankshaft until it stops against the special tool.

  1. Discard the bolt.

  1. Tighten M6 x 18 mm bolt hand-tight only.

  1. CAUTION:
    CAUTION:Make sure that a new bolt is installed.
    Special Tool(s): 205-072, 205-072-02
    Torque:
    Stage 1:
    100 Nm
    Stage 2:
    90°

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

  1. Torque: 20 Nm

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

  1. Apply sealant (bead diameter 3mm).
    Material: Silicone Sealant

  1. Torque: 10 Nm

Assembly|Installation > < General Procedures|Removal and Installation|Disassembly|Engine