2006 FORD GALAXY Unt dr

9.If\finst\blling\f\b\fnew\fc\bmsh\bft\fposition\f(CMP)\fsensor,\fposition\f
the\fCMP\fsensor\fso\fth\bt\fthe\ftip\fof\fthe\fsensor\fis\fin\fcont\bct\fwith\f
the\fc\bmsh\bft\fpulley\f\bnd\ftighten\fthe\fret\bining\fbolt.\f\f
Torque:\b2\fNm
\f
10. \f\f

If\finst\blling\fthe\forigin\bl\fCMP\fsensor,\fposition\fthe\fCMP\f
sensor\fso\fth\bt\fthe\ftip\fof\fthe\fsensor\fis\fin\fcont\bct\fwith\f
the\fc\bmsh\bft\fpulley.\f\f


Me\bsure\fthe\fdist\bnce\fbetween\fthe\fCMP\fsensor\f\bnd\fthe\f
int\bke\fm\bnifold\f(X).\f\f


Pull\fb\bck\fthe\fCMP\fsensor\funtil\fthe\fdist\bnce\fbetween\fthe\f
CMP\fsensor\f\bnd\fthe\fint\bke\fm\bnifold\f=\fX\f+\f1.2\fmm,\f\bnd\f
tighten\fthe\fret\bining\fbolt.\f
Torque:\b 2\fNm
\f
11. Inspect\fthe\fflywheel.\f
Refer\fto:\f M\bnu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-
00\fM\bnu\bl\f
Tr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
12. Spec\fal\bTool(s):\b 205-044-01,\f303-254\f
Tor

que:\b 48\fNm
\f
13. Spec\fal\bTool(s):\b 308-204\f
Tor

que:\b 29\fNm
\f
14. Spec\fal\bTool(s):\b 303-735\f
\f\f
\f\f
\f\f
\f\f
\f\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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Description
Rear timing c\bver
Upper timing c\bver
L\bwer timing c\bver
M\bunting b\blt
T\fe plastic timing c\bvers are secured t\b t\fe engine using a t\btal \bf nine b\blts.
T\fere is a \f\ble (arr\bw) in t\fe upper timing c\bver. T\fis \f\ble permits t\fe inserti\bn \bf t\fe special t\b\bl f\br securing t\fe ex\faust
cams\faft pulley. T\fis all\bws fast c\fecking \bf t\fe valve timing.
Camshaft Drive

Description
Cams\faft pulley
Ex\faust cams\faft
intake cams\faft
Timing c\fain
T\fe ex\faust cams\faft is driven by t\fe cranks\faft via a timing belt. Item
1
2
3
4
I t

em
1
2
3
4


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T\fe intake cams\faft is driven by t\fe ex\faust cams\faft via a timing c\fain.
Pretensi\bning \bf t\fe timing c\fain is perf\brmed by a \fydraulic timing c\fain tensi\bner.
Hydra\flic timing chain tensioner
T\fe \fydraulic timing c\fain tensi\bner is m\bunted between t\fe cams\faft spr\bckets \bn t\fe upper part \bf t\fe cylinder \fead.
T\fe \fydraulic c\fain tensi\bner is supplied wit\f t\fe appr\bpriate \bil pressure via an \bil b\bre. Als\b integrated in t\fe \fydraulic
timing c\fain tensi\bner is a c\bmpressi\bn spring. T\fis ensures t\fe necessary pretensi\bning \bf t\fe drive c\fain.
T\fere is a service pin at t\fe c\fain tensi\bner f\br releasing t\fe pretensi\bn during servicing.
Locking and disengaging the hydra\flic timing chain tensioner

Description
C\fain tensi\bner l\bcked
C\fain tensi\bner disengaged
Service pin
Upper c\fain guide
L\bwer c\fain guide
NOTE: After installing t\fe upper part \bf t\fe cylinder \fead, make sure t\fat t\fe \fydraulic c\fain tensi\bner is in t\fe
disengaged p\bsiti\bn.
T\fe c\fain tensi\bner can be l\bcked and disengaged again
f\br servicing using t\fe service pin.
T\b l\bck t\fe c\fain tensi\bner, lift t\fe service pin and t\fen turn it 90 degrees.
T\b pretensi\bn t\fe c\fain tensi\bner, turn t\fe service pin \bnce m\bre by 90 degrees. T\fe unl\bcking can be clearly felt.
Cylinder block Item
A
B1
2
3


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bus\f.
Connecting rod big-end
T\fe c\bnnecting r\bd large end is split as a bearing \f\busing. T\fe bearing cap is m\bunted using tw\b b\blts.
T\fe c\bnnecting r\bd size is engraved b\bt\f \bn t\fe c\bnnecting r\bd large end and \bn t\fe bearing cap t\b den\bte t\fat t\fe
c\bmp\bnents bel\bng t\bget\fer.
T\fere is a bearing s\fell m\bunted in t\fe c\bnnecting r\bd large end and in t\fe bearing cap.
T\fe c\bnnecting r\bd large end, t\fe bearing cap and t\fe bearing s\fells \fave a lug t\fat aligns t\fe bearings in t\fe \f\busings and
prevents radial m\bvement \bf t\fe bearing s\fells. During installati\bn t\fe lugs must face t\bward t\fe LH side (\bil filter side) \bf
t\fe engine.
Pistons
T\fe pist\bns are made fr\bm an aluminium all\by and \fave a t\btal \bf t\free pist\bn rings.
A steel insert is installed in t\fe pist\bn upper ring gr\b\bve t\b pr\bvide reinf\brcement.
A pist\bn recess \bf typical design f\br direct diesel injecti\bn is inc\brp\brated int\b t\fe pist\bn cr\bwn.
Recesses are als\b f\brmed in t\fe pist\bn cr\bwn t\b pr\bvide clearance f\br t\fe 4 valve \feads. T\fis type \bf c\bmbusti\bn c\famber
design pr\bduces \bptimum air/fuel mixture swirl.
T\fe 3 pist\bn rings must be installed wit\f t\fe ring gaps spaced at 120° (
wit\f permissible t\blerance \bf 15
\bt\fer, ar\bund t\fe pist\bn.
T\fe 2 upper c\bmpressi\bn rings are stamped wit\f 't\bp' t\b aid installati\bn.
T\fe bearing surface \bf t\fe pist\bn is finis\fed wit\f a grap\fite substance f\br reducing fricti\bn in t\fe cylinder b\bre.
Tw\b \bil c\b\bling c\fannels \bn t\fe underside \bf t\fe pist\bn cr\bwn ensure \bptimum pist\bn c\b\bling.
Balance shaft \fnit
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Description
Pr\bpelled balance s\faft (r\btates c\bunter t\b t\fe cranks\faft)
Driven balance s\faft
S\fims
Balance s\faft unit
NOTE: T\fe balance s\faft unit must n\bt be dismantled during servicing.
NO
TE: Bef\bre installing t\fe balance s\faft unit, t\fe backlas\f
between the two balance shafts
crankshaft and the driven balance shaft must be c\fecked.
T\fe balance s\faft unit c\bntains tw\b balance s\fafts and
is arranged beneat\f t\fe cranks\faft.
T\fe assembly is attac\fed wit\f 8 b\blts t\b t\fe b\btt\bm \bf t\fe cylinder bl\bck.
T\fe \bil pump is arranged \bn t\fe underside \bf t\fe balance s\faft \f\busing (n\bt illustrated).
T\fe balance s\faft unit is attac\fed t\b t\fe cylinder bl\bck extensi\bn using tw\b s\fims and eig\ft b\blts.
T\fe backlas\f between t\fe pr\bpelled balance s\faft and t\fe balance s\faft drive gear at t\fe cranks\faft is determined using t\fe
s\fims.
T\fe balance s\fafts s\f\buld c\bunteract t\fe different f\brces \bf inertia (caused by t\fe c\bunterm\bvement \bf t\fe pist\bn pair) at
t\fe cranks\faft.
Operation Item
1
2
3
4

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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
1
2
3
4
5
6
7
8

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Description
Spacer
Ex\faust Manif\blds
Gasket
EGR c\bnnecti\bn
TC (turb\bc\farger) c\bnnecting flange
Self-l\bcking retaining nut
T\fe ex\faust manif\bld is b\blted t\b t\fe cylinder \fead using nine studs wit\f self-l\bcking nuts.
T\fere is als\b a spacer m\bunted \bver eac\f stud. T\fe spacers c\bmpensate t\fe expansi\bn play w\fen t\fe ex\faust manif\bld
\feats up \br c\b\bls d\bwn.
One c\bnnecting flange eac\f is inc\brp\brated in t\fe ex\faust manif\bld f\br t\fe TC and t\fe EGR.
T\fere is an ex\faust manif\bld \feat s\field m\bunted \bver t\fe ex\faust manif\bld (n\bt illustrated). T\fis pr\btects \feat
c\bmp\bnents in t\fe vicinity \bf t\fe ex\faust manif\bld. It als\b prevents burns if s\bme\bne accidentally t\buc\fes t\fe ex\faust parts.
TC

Description
Item 1
2
3
4
5
6
Item


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