2006 FORD GALAXY lock

Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Engine AccessoriesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installation
Special Tool(s)
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-254\f
Locking\fTool,\fFlywheel\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-435-14B\f
Mounting\fPl\bte\ffor\f303-435-06
\f
1.Torque:\b 17\fNm\f
2. Torque:\b 48\fNm
\f
\f
\f
\f
\f
\f
\f\f
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Engine—Vehicles With: 6-Speed
Manual Transaxle - M66
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installation
Special Tool(s)
Ge

neral Equipment
303-122\f
Lifting\fBr\bcket,\fEngine
\f
Hose clamp remover/installer
Mounting table set
Retaining Strap 1.WARNING:\fM\bke\fsure\fth\bt\fthe\fengine\f
\bn

d\ftr\bnsmission\f\bssembly\fis\fon\fwooden\f
blocks\f\bnd\fsecured\fwith\fsuit\bble\fret\bining\f
str\bps.\f General \bqui\fment: Mo
unting\ft\bble\fset\f
Gen
eral \bqui\fment: Ret\bining\fStr\bp\f
2.Remove the S\fecial Tool(s): 303-122\f
3. To
rque: 48\fNm
\f
4. Torque: 48\fNm
\f
\f
\f
\f
\f\f
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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi (92kW/\b25PS) -
Engine \fata - \b00 PS
Engine \fata - \b25 PS
Lubricants, Fluids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Block \fimensions
Piston \fimensions
Descrip\bion
Code
Emi\b\bion le\fel
Firing order
Bore diameter
Stroke
Di\bplacement
Compre\b\bion ratio
Maximum power output at 3850 rpm
Maximum torque at 1800 rpm
Idle \bpeed
Maximum oil con\bumption
Descrip\bion
Code
Emi\b\bion le\fel
Firing order
Bore diameter
Stroke
Di\bplacement
Compre\b\bion ratio
Maximum power output at 3700 rpm
Maximum torque at 1800 rpm
Idle \bpeed
Maximum oil con\bumption
I\be\f
Ford Formula E SAE 5W-30 engine oil
Coolant
Sealant - oil pan to ladder frame
Sealant - ladder frame to cylinder block
Sealant - cam\bhaft bearing cap no. 1
Sealant - fuel pump pulley
Initial fill including oil filter
Ser\fice fill including oil filter
Ser\fice fill without oil filter
Descrip\bion
Cylinder bore diameter - Cla\b\b 1
Cylinder bore diameter - Cla\b\b 2
Main bearing parent bore diameter
Descrip\bion
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specific\btion.\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.\f
PCV\foil\fsep\br\btor\fis\ff\bulty\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\fm\bnifold.
\f
*
-
-CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\f\f
REFER\fto:\f Engine\fEmission\fControl \f(303-
08C

\fEngine\fEmission\fControl\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f
-\fLynx,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\f
Ch\br

ging\f\bnd\fControls\f-\fTurboch\brger\f-\f
2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f
-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
D\bm\bged\fg\bskets\for\fm\bting\f
surf\bces.\f
Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f\bre\f
w\brped.\f
V\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.\fCHECK\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.\f\f
REFER\fto:\f V\blve\fStem\fSe\bls \f(303-01E\f
Eng

ine\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\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\fnecess\bry.\fINSTALL\f\b\fnew\fcylinder\f
block\fif\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\f
REFER\fto:\f
Engine\fCooling \f(303-03D\f
Eng
ine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-\fLynx,\fDi\bgnosis\f
\bnd\fTesting).\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
*
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Engine\fwill\fnot\f
cr\bnkB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
REFER\fto:\fB\bttery\f(414-01,\fDi\bgnosis\f
\bnd\fTesting).\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\fSt\brting\fSystem\f(303-06,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brtFuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
W\bter\fin\ffuel\f(only\fdiesel\f
engine).\f
*Dr\bin\fthe\fw\bter\ffrom\fthe\ffuel\fsystem.\f\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Glow\fplug\ff\bulty\f(only\fdiesel\f
engine).\f
*
CHECK\fthe\fglow\fplugs.\fINSTALL\fnew\f
glow\fplugs\f\bs\fnecess\bry.\f\f
REFER\fto:\fGlow\fPlug\fSystem\f(303-07,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fthe\fv\blve\ftiming.\f\f
REFER\fto:\fV\blve\fCle\br\bnce\fAdjustment\f
(303-01,\fGener\bl\fProcedures).\f
*
Broken\for\fd\bm\bged\ftiming\f
belt/timing\fch\bin\for\f
pulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\frough.Fuel\fsystem.\f
*CHECK\fthe\ffuel\fsystem.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Exh\bust\fsystem\fblocked.\f
*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\fExh\bust\fSystem\f(309-00,\f
Description\f\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\fsprocket\f
or\fpulley/sprocket\fd\bm\bged.
\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Ignition\ftiming\fincorrect\f
(only\fpetrol\fengines).\f
*CHECK\fthe\felectronic\fengine\fcontrols.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Noisy\frunningEngine\f\buxili\bry\f
components\floose\for\f
d\bm\bged.\f
*CHECK\fengine\f\buxili\bry\fcomponents\ffor\f
d\bm\bge\for\flooseness.\fCHECK\f\bnd\f\bdjust\f
v\blve\ftiming.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning,\fIncorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
*
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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Timing Belt
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen

eral Equipment
Removal
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-193\f
Timing\fPeg,\fCr\bnksh\bft\fTDC\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-393\f
Locking\fTool,\fFlywheel\f
303-651\f
Remover,\fC\bmsh\bft\fSprocket\f
C\bble\fties
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. Refer\fto:\f V\blve\fCover\f(303-01E\fEngine\f-\f1.8L\f
Dur

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. \f
4. \f
\f
\f
\f
\f
\f
\f\f
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15. \f
16. \f
17. CAUTIONS:\f
M\b

ke\fsure\fth\bt\fthe\fcr\bnksh\bft\fis\fnot\f
rot\bted\fwhile\fthe\fspeci\bl\ftool\fis\finst\blled.\f
Only\frot\bte\fthe\fcr\bnksh\bft\fclockwise.\f
1. Remove\fthe\fcylinder\fblock\fbl\bnking\fplug\f \bnd

\f
Install the S\fecial Tool(s): 303-193\f
2. In

stall the S\fecial Tool(s): 303-393\f
18. Refer\fto:\fSt\brter\fMotor\f(303-06D\fSt\brting\f
Sys
tem\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
19. Det\bch\fthe\fch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\f position\fit\fto\fone\fside.\f
20. General \bqui\fment: Trolley\fj\bck\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Installation 26.
S\fecial Tool(s): 3
03-651\f
1. \f
\f
Check\fthe\ftiming\fbelt\ftensioner\f\bnd\fm\bke\f
su

re\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\f
rot\btes\fclockwise\ffreely.\f

Move\fthe\ftiming\fbelt\ftensioner\f\bdjustment\f
\brm

\fto\fthe\f3\fo'clock\fposition.\f

Do\fnot\ffully\ftighten\fthe\ftiming\fbelt\f
te

nsioner\fret\bining\fbolt\f\bt\fthis\fst\bge.\f
2. \f\f

The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\f
freely\fon\fthe\fc\bmsh\bft\ft\bper.\fTighten\fthe\f
c\bmsh\bft\fpulley\fbolt\ffinger\ftight\f\bnd\fthen\f
loosen\fby\fone-h\blf\fturn.\f\f

Inst\bll\fthe\ftiming\fbelt\fwith\fthe\fdirection\f
\brr

ows\fin\fthe\fdirection\fof\fengine\frot\btion.\f
3.
Tension\fthe\ftiming\fbelt\fcounterclockwise\funtil\fthe\f
pointer\fis\fpositioned\fbetween\fthe\fsides\fof\fthe\f
window.\f\f
Torque: 50\fNm
\f
4. S\fecial Tool(s): 205-072\f
Tor

que: 50\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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