2006 FORD GALAXY engine

\f\f\fescription
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Roller\fc\bm\ffollower\f
Hydr\bulic\ft\bppet\f
The\finlet\fv\blves\f\bre\fm\bde\fentirely\fof\fone\fm\bteri\bl.\fThe\fhe\bds\f\bnd\fstems\fof\fthe\fexh\bust\f
v\b
lves\f\bre\fm\bnuf\bctured\ffrom\fdifferent\fm\bteri\bls\f\bnd\f\bre\fjoined\fto\fone\f\bnother\fby\fme\bns\f
of\ffriction\fwelding.\f
By\fusing\froller\ffollowers,\fit\fh\bs\fbeen\fpossible\fto\fkeep\fv\blve\f\bctu\btion\ffriction\flosses\flow.\f
V\blve\fcle\br\bnce\f\bdjustment\fis\fdone\f\butom\btic\blly\fby\fthe\fhydr\bulic\ft\bppets.\fAs\f\b\fresult,\f
there\fis\fno\fneed\fto\f\bdjust\fthe\fv\blve\fcle\br\bnces.\f
The\fhydr\bulic\ft\bppets\f\bre\fconnected\fwith\fthe\fengine's\foil\fcircuit\fby\foil\fports\fc\bst\finto\fthe\f
cylinder\fhe\bd.\f
Camshafts
\f\f
\fescription
Exh\bust\fc\bmsh\bft\f
Drive\f-\ffuel\fpump\f
Item
1
2
3
4
Item 1
2
\f
Part Number -
-
-
-
\f
Part Number-
-
-
Стр. 6 из 14
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\f\f\fescription
Timing\fbelt\fpulley\f-\fexh\bust\fc\bmsh\bft\f
Timing\fch\bin\ftensioner\f
Exh\bust\fc\bmsh\bft\fsprocket\f
Inlet\fc\bmsh\bft\fsprocket\f
The\ftiming\fch\bin\ftensioner\fis\f\btt\bched\fto\fthe\fupper\fp\brt\fof\fthe\fcylinder\fhe\bd,\fbetween\fthe\f
c\b
msh\bft\fsprockets.\f
Two\fsecuring\fbolts\f\bre\fused\fto\fsecure\fthe\fch\bin\ftensioner.\f
\f\f
\fescription
Timing\fch\bin\ftensioner\fhousing\f
Spring\f
Timing\fch\bin\fguide\f
Oil\fbore\f
The\ftiming\fch\bin\fguide\fis\fm\bde\fof\fpl\bstic.\f
Ti

ming\fch\bin\fguide\fwe\br\fis\fcompens\bted\ffor\fby\f\b\fspring\flo\bded\ftiming\fch\bin\ftensioner.\f
Bec\buse\fthe\ftiming\fch\bin\ftensioner\fis\fconnected\fto\fthe\fengine\foil\fsupply\fcircuit,\fthe\f
components\f\bre\flubric\bted\f\bnd\fch\bin\fnoise\fis\freli\bbly\fprevented.\f
A\fsecond\ftiming\fch\bin\fguide\fis\f\btt\bched\fto\fthe\fcylinder\fhe\bd\flower\fsection.\f
Timing chain
\f\f
Item 1
2
3
4
Item 1
2
3
4 \f\fPart Number
-
-
-
-
\f\f
Part Number-
-
-
-
\f\f
Part Number
Стр. 8 из 14
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Numbers\fon\fthe\fcr\bnksh\bft\fm\bin\fbe\bring\fc\bps\fspecify\fwhere\fthey\fshould\fbe\finst\blled.\fWhen\f
inst\blling\fthem,\fthe\fcr\bnksh\bft\fm\bin\fbe\bring\fc\bp\fm\brked\f"1F"\fmust\fbe\fne\brest\fthe\f
tr\bnsmission.\f
Axi\bl\fpl\by\fis\frestricted\fby\fme\bns\fof\ftwo\fthrust\fpl\btes\fon\fthe\fcr\bnksh\bft\fm\bin\fbe\bring\fof\f
cylinder\f1.\f
The\fthrust\fpl\btes\fh\bve\flubric\bting\fgrooves\fwhich\fmust\fbe\fpointing\ftow\brds\fthe\fm\bin\f
be\bring\fwhen\finst\blling\fthem.\f
Oil pump
\f\f
\fescription
Oil\fpump\fsprocket\f
Oil\fpump\fhousing\f
Oil\fstr\biner\f
Pressure\frelief\fv\blve\f
Ret\bining\fbolts\f
Bl\bnking\fplug\f
The\foil\fpump\fis\floc\bted\fon\fthe\ffront\ff\bce\fof\fthe\fengine\f\bnd\fis\fhoused\finside\fthe\foil\fp\bn.\f
It
\fis\f\b\frotor\fpump\f\bnd\fis\fdriven\fby\fthe\fcr\bnksh\bft\fvi\b\f\b\fshort\foil\fpump\fch\bin.\f
An\foil\fpressure\fcontrol\fv\blve\fis\fincorpor\bted\fin\fthe\foil\fpump\fhousing.\fIt\fopens\fwhen\fthe\foil\f
pressure\fre\bches\f\bbout\f8\fb\br.\f
Oil filter/oil cooler unit Item
1
2
3
4
5
6
\f
Part Number -
-
-
-
-
-
\f\f
Стр. 12 из 14
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\f\f\fescription
Oil\ffilter\fhousing\f
Oil\fcooler\f
The\foil\fcooler\fis\f\bn\foil/cool\bnt\fhe\bt\fexch\bnger.\f
Th

e\foil\ffilter/oil\fcooler\funit\fis\floc\bted\fon\fthe\fside\fof\fthe\fcylinder\fblock\fin\fline\fwith\fcylinder\f2.\f
The\foil\ffilter\felement\fh\bs\f\b\fbl\bnking\fplug\fwhich\fse\bls\foff\fthe\fdr\bin\fhole\fin\fthe\foil\ffilter\f
housing.\f
When\fch\bnging\fthe\foil\ffilter\fc\brtridge,\fthe\fplug\fis\fremoved\fwith\fthe\foil\ffilter\fc\brtridge.\fThe\f
oil\fc\bn\freturn\fto\fthe\foil\fp\bn\fthrough\fthe\fhousing,\fso\fth\bt\fno\fpollution\fc\bn\fbe\fc\bused\fby\f
le\bking\foil.\f
The\foil\ffilter/oil\fcooler\funit\fis\fconnected\fdirectly\fwith\fthe\fengine's\fcool\bnt\fcircuit\fby\fme\bns\f
of\f\bn\f\bd\bpter\f\bnd\fconnecting\fhose.\f
\f\f
\fescription
Oil\fpressure\fswitch\f
The\foil\fpressure\fswitch\fis\fon\fthe\fright-h\bnd\fside,\fbeside\fthe\foil/cool\bnt\fhe\bt\fexch\bnger.\f
Th

e\foil\fpressure\fswitch\fmonitors\fthe\fminimum\foil\fpressure\fof\f0.5\fb\br.\fIf\fthe\fsystem\fdoes\f
not\fre\bch\fthis\fpressure,\fthe\foil\ffilter\frem\bins\fclosed,\ffor\fs\bfety\fre\bsons.\f
Oil spray tubes Item
1
2
I t

em
1
\f
Part Number -
-
\f\f
Part Number-
Стр. 13 из 14
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\f\f\fescription
B\bnjo\fbolts\f
Oil\fspr\by\ftubes\f
The\fpiston\fskirts\f\bre\fcooled\ffrom\fbelow\fusing\foil\ffrom\fthe\foil\fspr\by\ftubes.\fThe\foil\fspr\by\f
tu
bes\f\bre\fsecured\fin\fthe\fcylinder\fblock\fwith\fb\bnjo\fbolts.\f
The\fb\bnjo\fbolts\f\bre\fconnected\fto\fthe\fengine\foil\fcircuit.\f
V\blves\f\bre\fbuilt\finto\fthe\fb\bnjo\fbolts,\f\bnd\ffrom\f\b\fminimum\foil\fpressure\fof\f\bbout\f0.5\fb\br\fthey\f
supply\fthe\foil\fspr\by\ftubes.\f Item
1
2
\f
Part Number -
-
Стр. 14 из 14
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Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fiagnosis and Testing
Special Tool(s)
Gen

eral Equipment
Materials
Specification
WSK-M2G349-A7\f\f
Inspection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. \b.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
3

. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Visual Inspection Chart
S y

mptom Chart
Compression\fTest\fAd\bpter\f
303-1056\f\f
Ford\fdi\bgnostic\fequipment
Name
Adhesive\f-\fLoctite\f243
Mechanica\bE\bectrica\b

Cool\bnt\fle\bks\f\f

Oil\fle\bks\f\f

Fuel\fsystem\fle\bks\f\f

Visibly\fd\bm\bged\for\fworn\fp\brts\f\f

Loose\for\fmissing\fnuts\for\fbolts\f
Fuse(s)\f\f

Loose\for\fcorroded\fconnector(s)\f\f

Control\fmodule\f\f

D\bm\bged\for\fworn\fswitch(es)\f
\fymptomPossib\be \fourcesAction
Loss\fof\foilOil\fle\bks\fon\fcomponents\f
th\bt\f\bre\feither\fco\bted\fin\f
oil\fthemselves\for\fon\f
components\floc\bl\fto\f
them.\f
*CHECK\ffor\fevidence\fof\foil\fle\bks\fon\f
components.\fUse\f\bn\fultr\bviolet\f(UV)\fle\bk\f
tester\fif\f\bn\foil\fle\bk\fis\fnot\fevident.\fINSTALL\f
new\fg\bskets\for\fcomponents\f\bs\frequired.\f
*
Intern\bl\for\fextern\bl\fle\bk\f
\bt\fthe\foil\fcooler.\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\f\b\ffilm\f
of\foil\fon\fthe\fcool\bnt\fsurf\bce.\fINSTALL\f\b\fnew\f
oil\fcooler\for\foil\fcooler\fg\bsket.\f
*
Le\bk\f\bt\fthe\fcr\bnksh\bft\f
se\bl.\f
*INSTALL\f\b\fnew\fcr\bnksh\bft\fse\bl.\f
*
Le\bks\ffrom\foil\fc\brrying\f
components\for\fb\bsic\f
engine.\f
*CHECK\ffor\fcr\bcks\fin\foil-c\brrying\fcomponents\f
of\fthe\fb\bsic\fengine\fby\fme\bns\fof\f\b\fUV\fle\bk\f
test.\fINSTALL\fnew\fcomponents\for\fse\bls\f\bs\f
*
\f
Стр. 1 из
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necess\bry.\f
Oil\fconsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\fused\f
\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\fCh\bnge\f
the\fengine\foil\fto\fthe\fspecific\btion.\fREFER\fto:\f
Specific\btions \f(303-01F\fEngine\f-\f2.0L\f
Dur

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\f
Specific\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\f
blocked.\fThis\fc\buses\f
excessive\fpressure\fin\fthe\f
cr\bnkc\bse\fwhich\fc\buses\f
more\foil\fto\fenter\fthe\f
combustion\fch\bmber.\f
PCV\foil\fsep\br\btor\fis\f
f\bulty\f\bnd\fengine\foil\fc\bn\f
enter\fthe\fcombustion\f
ch\bmber\fthrough\fthe\f
int\bke\fm\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\fREFER\fto:\f
Engine\fEmission\fControl \f(303-08D\fEngine\f
Emi

ssion\fControl\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/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,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\fturboch\brger.\fREFER\fto:\f
Turboch\brger \f(303-04J\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/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\f
m\bting\fsurf\bces.\f
Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f
\bre\fw\brped.\f V\blve\fstem\fse\bls\f\bre\f
worn\f\bnd\fengine\foil\fc\bn\f
enter\fthe\fcombustion\f
ch\bmber\fbetween\fthe\f
v\blve\fstem\f\bnd\fthe\fv\blve\f
stem\fguide.\f
*
-
-CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\ffor\f
d\bm\bge.\f
Remove\fthe\fcylinder\fhe\bd.\fREFER\fto:\f
Cylinder\fHe\bd\f(303-01F\fEngine\f-\f2.0L\f
Du r

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).CHECK\fthe\fm\bting\ff\bces,\f
cylinder\fhe\bd\fg\bsket\f\bnd\fthe\fevenness\fof\fthe\f
cylinder\fhe\bd\f\bnd\fengine\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fse\bls.\fREFER\fto:\f V\blve\f
Ste

m\fSe\bls \f(303-01F\fEngine\f-\f2.0L\fDur\btorq-
TDC

i\f(85kW/115PS)\f-\fDW/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
*
-
-
Piston\fring\for\fcylinder\f
liner\fwe\br.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
D\bm\bged\fcylinder\fliners\f
or\fexcessive\fcle\br\bnce\fof\f
engine\fcomponents.\f Pistons.\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\fCylinder\fliners.\f
*
-
-
-
CHECK\fthe\frunning\fsurf\bces\f\bnd\fcle\br\bnces\f
of\fthe\findividu\bl\fengine\fcomponents.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fINSTALL\f\b\f
new\fcylinder\fblock\fif\fnecess\bry.\f
Check\fthe\fpistons\f\bnd\fpiston\frings.\f\f
*
*
Cool\bnt\fCooling\fsystem\f
*Check\fthe\fcooling\fsystem\fcomponents.\f
*
Стр. 2 из 13
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consumptioncomponents.\fREFER\fto:\fEngine\fCooling \f(303-03F\fEngine\f
Coo
ling\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f
-\fDW,\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\fd\bm\bge.\f
CHECK\fthe\fcylinder\fhe\bd\ffor\fdistortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\f
such\f\bs\fcylinder\fliners\f
\bnd\fcylinder\fhe\bd\f
combustion\fch\bmber.\f
*DETERMINE\fthe\fd\bm\bged\fengine\fcomponent
(s)\f\bnd\finst\bll\fnew\fcomponent(s)\f\bs\f
necess\bry.\f
*
Engine\fwill\fnot\f
cr\bnkB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\fREFER\fto:\f
St\brting\fSystem \f(303-06E\fSt\brting\fSystem\f-\f
2.0

L\fDur\btorq-TDCi\f(85kW/115PS)\f-
\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brt
Fuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
W\bter\fin\ffuel.\f
*Dr\bin\fthe\fw\bter\ffrom\fthe\ffuel\fsystem.\f\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\fREFER\fto:\f Fuel\f
Fil
ter \f(310-01C\fFuel\fT\bnk\f\bnd\fLines\f-\f2.0L\f
Dur

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Engine\fint\bke\f\bir\fsystem.\f*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
*
Glow\fplug\ff\bulty.\f
*CHECK\fthe\fglow\fplugs.\fINSTALL\fnew\fglow\f
plugs\f\bs\fnecess\bry.\fREFER\fto:\f Glow\fPlug\f
(30

3-07D\fGlow\fPlug\fSystem\f-\f2.0L\fDur\btorq-
TDCi\f(85kW/115PS)\f-\fDW/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
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fthe\fv\blve\ftiming.\fREFER\f
to:\f Timing\fBelt \f(303-01F\fEngine\f-\f2.0L\f
Dur

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Broken\for\fd\bm\bged\f
timing\fbelt/timing\fch\bin\f
or\fpulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fREFER\fto:\f Timing\fBelt\f(303-
01F\f
Engine\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\f
DW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\fFuel\fch\brging\fsystem.\f
*CHECK\fthe\ffuel\fch\brging\fsystem.\fREFER\fto:\f
Fuel\fCh\brging\f\bnd\fControls\f(303-04E\fFuel\f
Ch \br

ging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
*
Стр. 3 из
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