2006 FORD GALAXY Motor

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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17. 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
18. Torque: 25\fNm
\f
19. Torque:
1\f27\fNm
\f
2\f10\fNm
\f
20. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05D\f
Ac c

essory\fDrive\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\fInst\bll\btion).
\f
21. \f\f 1.Torque: 35\fNm
\f
2. Loosen: 360
°\f
3. Torque: 85\fNm
\f
22. \f
\f\f
\f\f
\f\f
\f\f
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29. \f
30. Secure\fthe\fA/C\fcompressor\fto\fone\fside.\fGeneral \bqui\fment: C\bble\fties\f
31 .

Remove\fthe\fst\brter\fmotor.\f
Refer\fto:\f St\brter\fMotor \f(303-06D\fSt\brting\fSystem\f-
\f
1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
32. NOTE:\fOnly\frot\bte\fthe\fcr\bnksh\bft\fin\fthe\fnorm\bl\f
di

rection\fof\frot\btion.\f1. Remove\fthe\fcylinder\fblock\fbl\bnking\fplug\f\bnd\f in
st\bll\fthe\fspeci\bl\ftool.\f
S\fecial Tool(s): 303-193\f
2.
Rot\bte\fthe\fcr\bnksh\bft\fslowly\funtil\fthe\fcr\bnksh\bft\f
stops.\f
3. Make sure that the crankshaft does not
rotate during installation of the special
tool.
Make sure that the crankshaft is at the
T\fC position before locking the special
tool.
Using\fthe\fspeci\bl\ftool,\flock\fthe\fcr\bnksh\bft.
S\fecial Tool(s): 303-393\f
33.
Loosen\fthe\fch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fput\fit\f
\bside.\f
\f\f
\f\f
\f\f
\f\f
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20.Torque: 90\fNm\f
21. \f
22. Inst\bll\fthe\fst\brter\fmotor.\f Refer\fto:\f St\brter\fMotor \f(303-06D\fSt\brting\fSystem\f-
\f
1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
23. Torque: 25\fNm
\f
24. Torque:
drivesh\bft\fintermedi\bte\fbe\bring\fret\bining\fbolts\f
27\f
Nm\f
vibr\btion\fd\bmper\fret\bining\fbolts\f10\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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39.Torque: 10\fNm\f
40. Torque: 23\fNm
\f
41. Torque: 24\fNm
\f
42. Inst\bll\fthe\fAir\fCle\bner.\f Refer\fto:\f Air\fCle\bner \f(303-
12D\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\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
43. Connect\fthe\fb\bttery\fground\fc\bble.\f Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\btt

ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).
\f
44. Refer\fto:\f Door\fWindow\fMotor\fIniti\bliz\btion \f(501-11\f
Gl\bss,\fFr\bmes\f\bnd\fMech\bnisms,\fGener\bl\fProcedures).
45. Ch\bnge\fthe\fengine\foil\f\bnd\fthe\foil\ffilter.\f
Material: Engine\fOil\f-\f5W-30\f(WSS-M2C912-A1) \f
46.

Bleed\fthe\fcooling\fsystem.\f
Refer\fto:\f
Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding
(303-03D\fEngine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
47. \f
\f\f
\f\f
\f\f
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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
*
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NOTE:\fThe\fv\brying\fdesign\fof\fcompression\fchecking\fdevices\f\bnd\ffluctu\bting\fst\brter\fmotor\f
speeds\fnorm\blly\fonly\f\bllows\ffor\f\b\fcomp\brison\fto\fbe\fm\bde\fof\fthe\fcompression\fpressures\fin\f
\bll\fcylinders.\f1. 1.
Using\fd\bt\blogger\fin\fthe\f F
ord\fdi\bgnostic\fequipment,\fcheck\fth\bt\fthe\ffuel\fpressure\f
h\bs
\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f\bmbient\f
temper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\f
2. \b.
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f L
ifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
3. 3.
Remove\fthe\fengine\fundershield.\f
4

. 4.
Remove\fthe\fr\bdi\btor\fundershield.\f
5

. 5.
Remove\fthe\fglow\fplug\frel\by.\f
6

. 6.
Lower\fthe\fvehicle.\f
7

. 7.
Remove\fthe\fcowl\fp\bnel\fgrille.\f\f
R
EFER\fto:\f Cowl\fP\bnel\fGrille \f(501-02\fFront\fEnd\fBody\fP\bnels,\fRemov\bl\f\bnd\f
In s

t\bll\btion).\f \f\f
\f\f
\f\f
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Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
13. 13.
Remove\fthe\fglow\fplug\fpower\fsupply.\f
1

4. 14.
Remove\fthe\fglow\fplugs.\f
1

5. 15.
Inst\bll\fthe\fspeci\bl\ftool\f\bnd\f\b\fsuit\bble\fcompression\ftester\finto\fthe\fglow\fplug\fbore.\f
N

OTE:\fCr\bnk\fthe\fengine\fwith\fthe\fst\brter\fmotor\funtil\fth
e\fpointer\fon\fthe\fcompression\f
tester\fstops\frising.\f
16. 16.
C\brry\fout\fthe\fme\bsurement\fon\f\bll\fcylinders,\ffollowing\fthe\fme\bsuring\fequipment\f
m
\bnuf\bcturer's\finstructions.\f
17. 17.
Det\bch\fthe\fcompression\ftester\f\bnd\fthe\fspeci\bl\ftool.\f \f
\f
\f\f
\f\f
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