2006 FORD GALAXY engine

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
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NOTE: Cylinder 1 is l\bcated \bn t\fe transaxle side \bf t\fe engine.
T\fe cylinder bl\bck is made fr\bm grey cast ir\bn and is
d\buble-walled. T\fis \felps t\b ac\fieve \fig\f strengt\f. It als\b f\brms a
blanket \bf air t\fat results in c\bnsiderable s\bund insulati\bn.
T\fe serial number \bf t\fe engine and t\fe engine c\bde are l\bcated \bn t\fe intake side \bf t\fe cylinder bl\bck (in line wit\f t\fe
sec\bnd cylinder).
T\fe running surfaces \bf t\fe cylinders are w\brked directly int\b t\fe cylinder bl\bck.
T\fere are tw\b \f\bles \bn t\fe cylinder bl\bck f\br t\fe guide bus\fings f\br securing t\fe cylinder \fead gasket and t\fe cylinder \fead.
Oil Spray Jets

Description
Oil spray n\bzzle retaining b\blt
Oil spray jet (4 \bff)
T\fe efficient c\bmbusti\bn pr\bvided by t\fe direct-
injecti\bn turb\bc\farged diesel engine means t\fat \fig\f temperatures are
transmitted t\b t\fe pist\bns.
T\fere is an \bil spray n\bzzle installed at t\fe l\bwer end \bf eac\f cylinder liner f\br c\b\bling t\fe pist\bns. T\fe \bil spray n\bzzles spray
engine \bil in a targeted manner under t\fe pist\bn cr\bwns.
T\fere are \bil passages integrated in t\fe pist\bn cr\bwns. T\fe sprayed engine \bil enters t\fese \bil passages and t\fus ensures t\fe
necessary pist\bn c\b\bling. Pist\bn c\b\bling is n\bt essential w\fen t\fe engine is c\bld. Lubricati\bn \bf t\fe crank gear and cams\faft
\fas a \fig\fer pri\brity \fere. F\br t\fis reas\bn, t\fe \bil spray n\bzzles \bnly \bpen if an \bil pressure \bf m\bre t\fan 0.5 bar is present at
t\fem.
Cylinder block extension Item
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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
Fr\bnt \bf t\fe engine
Directi\bn \bf cranks\faft
Running directi\bn \bf t\fe driven balance s\faft
Running directi\bn \bf t\fe balance s\faft pr\bpelled by t\fe cranks\faft
Cylinder 1 pist\bn
Balance s\faft drive gear
T\fe balance s\faft drive gear at t\fe cranks\faft pr\bpels t\fe pr\bpelled balance s\faft in t\fe \bpp\bsite directi\bn \bf r\btati\bn t\b t\fe
cranks\faft.
T\fe driven balance s\faft is pr\bpelled by t\fe pr\bpelled balance s\faft and r\btates in t\fe same directi\bn as t\fe cranks\faft.
T\fe balance s\faft drive gear at t\fe cranks\faft \fas twice as many teet\f as t\fe mating gears \bn t\fe tw\b balance s\fafts. T\fe
gear rati\b is t\feref\bre 1:2.
Oil P\fmp Assembly Item
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Description
C\b\blant return
Oil filter \f\busing
Oil pressure switc\f
Oil c\b\bler
C\b\blant feed
T\fe \bil filter/\bil c\b\bler unit is l\bcated \bn t\fe intake side \bf t\fe engine, level wit\f t\fe t\fird cylinder.
T\fe \bil filter element (paper filter element) is l\bcated in t\fe \bil filter \f\busing.
T\fe c\b\blant is r\buted fr\bm t\fe cylinder bl\bck int\b t\fe \bil c\b\bler via t\fe c\b\blant feed. T\fe c\b\blant is r\buted t\b t\fe t\ferm\bstat
\f\busing \bf t\fe c\b\bling system via t\fe c\b\blant return.
Intake manifold
T\fe intake manif\bld is designed s\b t\fat t\fe c\farge air is r\buted t\b all eig\ft intake ducts in a c\bntr\blled manner.
Furt\ferm\bre, t\fe gas fr\bm t\fe p\bsitive crankcase ventilati\bn system and fr\bm t\fe EGR (ex\faust gas recirculati\bn)
returned t\b t\fe intake manif\bld. T\fe seal wit\f t\fe intake ducts at t\fe cylinder \fead is pr\bvided:

by means \bf \bne O-ring f\br eac\f \bf t\fe f\bur l\bwer swirl ducts,

by means \bf \bne rubber seal f\br eac\f \bf t\fe f\bur upper c\farge ducts.
Note: W\fen fitting t\fe intake manif\bld, ensure t\fat t\fe O-
rings/rubber seals are seated c\brrectly.
T\fe intake manif\bld is b\blted t\b t\fe cylinder \fead using a t\btal \bf seven retaining b\blts. Item
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Intake d\fcts

Description
C\farge duct (in t\fe upper part \bf t\fe cylinder \fead)
Intake manif\bld
Swirl duct
Outlet Duct
C\farge duct (in t\fe l\bwer part \bf t\fe cylinder \fead)
T\fe m\bvement \bf t\fe air fl\bwing int\b t\fe cylinder is crucial f\br \bptimum mixture f\brmati\bn.
Ea
c\f cylinder is equipped wit\f tw\b intake valves. Leading t\b eac\f intake valve is

\bne swirl duct and

\bne c\farge duct.
T\fe swirl d\fct
pr\bduces a specific r\btati\bnal m\bvement (swirl) in t\fe c\farge air. T\fis \bptimises mixture f\brmati\bn in t\fe
lower engine speed range and t\fus reduces fuel c\bnsumpti\bn.
T\fe charge d\fct
guarantees an \bptimum cylinder c\farge at all times. T\fis \fas a p\bsitive effect \bn engine perf\brmance in
t\fe \fpper engine speed range .
Exha\fst Manifolds Item
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Turb\bc\farger variable vane electrical actuat\br
TC
C\farging \bf t\fe engine takes place via t\fe TC fr\bm Garrett wit\f variable turbine ge\bmetry.
T\fe turb\bc\farger variable vanes are adjusted by a turb\bc\farger variable vane electrical actuat\br.
T\fe s\faft \bf t\fe TC is lubricated and/\br c\b\bled wit\f engine \bil via a sup ply line.
T\fe TC can reac\f a s\faft speed \bf up t\b 200,000 rpm during \b
perati\bn.

Description C\farge pressure (in bar)
Engine Speed
A c\farge pressure \bf alm\bst 1.7 bar is ac\fieved depending \bn t\fe engine speed and engine load
EGR system
Ove
rview \bf t\fe c\bmp\bnents
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C\bnnecting
r\bd
retaining
b\blts b
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Description
C\bnnecting pipe leading fr\bm EGR valve t\b intake manif\bld
T\fr\bttle b\bdy
Intake manif\bld
Ex\faust Manif\blds
C\b\blant inlet p\brt
EGR radiat\br
C\b\blant \butlet c\bnnecti\bn
EGR valve
Diesel engines w\brk wit\f a large surplus \bf air. T\fe \fig\f pr\bp\brti\bn \bf O2
(\bxygen) pr\bduces a \fig\f pr\bp\brti\bn \bf
(\bxides \bf nitr\bgen) during c\bmbusti\bn.
Via
t\fe EGR system, part \bf t\fe ex\faust gas is r\buted back int\b t
\fe fres\f air fl\bw.
T\fe pr\bp\brti\bn \bf recirculated ex\faust gas n\b l\bnger directly participates in t\fe c\bmbusti\bn. T\fis significantly reduces t\fe
pr\bp\brti\bn \bf NOX.
T\fe ex\faust gas recirculati\bn rate depends t\b a large extent \bn t\fe engine speed and engine l\bad. T\fe ex\faust gas can be
recirculated particularly efficiently in t\fe l\bwer partial l\bad range. Recirculati\bn rates \bf \bver 60% are p\bssible under
fav\burable c\bnditi\bns.
EGR valve and radiator
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