2006 FORD GALAXY engine

headlight bulb power steering radio ESP inoperative clutch drain bolt

Page 1581 of 4402

$FORD GALAXY 2006 Service Repair Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - Turboch\brger - 1.8L Dur\btorq-TDCi (74kW/100PS) - Ly\fx/1.8L Dur\btorq- TDCi (92kW/125PS) - Ly\fx - Turboch\brger S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Des$

Page 1582 of 4402

$FORD GALAXY 2006 Service Repair Manual The\fturboch\brger\fbe\brings\f\bre\fsupplied\fwith\foil\ffrom\fthe\fengine.\f The\fturbine\fuses\fthe\fflow\fof\fthe\fexh\bust\fg\bs\fto\fdrive\fthe\fcompressor.\fThe\fcompressor\f dr\bws\f\bir\fthro$

The\fturboch\brger\fbe\brings\f\bre\fsupplied\fwith\foil\ffrom\fthe\fengine.\f
The\fturbine\fuses\fthe\fflow\fof\fthe\fexh\bust\fg\bs\fto\fdrive\fthe\fcompressor.\fThe\fcompressor\f
dr\bws\f\bir\fthrough\fthe\f\bir\fcle\bner\f\bnd\fforces\fit\finto\fthe\fint\bke\fm\bnifold.\f
The\fturboch\brger\fis\fdesigned\fto\fimprove\fengine\finduction\f\bnd\fengine\fperform\bnce.\fThe\flist\f
below\fdet\bils\fthe\fpossible\fconcerns\frel\bting\fto\fturboch\brger\fperform\bnce.\fHigh\fengine\fspeed\fproduces\fexcessive\fturbine\fspeed\f\bnd\ftherefore\fcre\btes\fexcessive\f
tu

rboch\brger\fboost\fpressure.\f\f
Low\fengine\fspeed\fdoes\fnot\fproduce\fsufficient\fturbine\fspeed\f\bnd\ftherefore\fnot\fenough\f
tu

rboch\brger\fboost\fpressure\fis\f\bchieved.\f
The\fturboch\brger\fdoes\fnot\fh\bve\f\b\fw\bsteg\bte\fcontrol\fv\blve.\fInste\bd,\fit\fh\bs\fv\bri\bble\f
t u

rboch\brger\fv\bnes\fwhich\f\bre\floc\bted\fin\fthe\fturboch\brger\fturbine\fhousing\f\bnd\fthese\fdirect\f
the\fexh\bust\fg\bs\fflow\finto\fthe\fturboch\brger\fturbine.\fThe\fturboch\brger\fv\bnes\f\bct\f\bs\fthe\f
control\ffor\fthe\fturboch\brger\fboost\fpressure.\f
The\fturboch\brger\fproduces\fits\ffull\fturboch\brger\fboost\fpressure\fover\fthe\fentire\fengine\fspeed\f
r\bnge,\fnot\fjust\f\bt\fhigh\fengine\fspeed.\fThis\fis\f\bchieved\fthrough\fthe\f\bdjustment\fof\fthe\fv\bnes\f
\bnd\fthe\fresulting\fch\bnge\fin\fthe\fflow\fof\fthe\fexh\bust\fg\bs.\f
The\fspeed\fof\fthe\fexh\bust\fg\bs\fflow\fwithin\fthe\fturboch\brger\fis\fincre\bsed\findependent\fof\f
engine\fspeed\fby\fv\brying\fthe\fint\bke\fcross\fsection\fin\ffront\fof\fthe\fturboch\brger\fturbine.\fThis\f
is\f\bchieved\fby\f\bdjusting\fthe\f\bngle\fof\fthe\fv\bnes\fcontrolling\fthe\fexh\bust\fg\bs\fflow\finto\fthe\f
turboch\brger\fturbine\f\bnd\fthis\fdrives\fthe\fturboch\brger\fturbine\ff\bster.\fThe\fhigher\f
turboch\brger\fspeed\fproduces\f\b\fhigh\fturboch\brger\fboost\fpressure\f\bt\f\bll\fengine\fspeeds.\f
The\fpowertr\bin\fcontrol\fmodule\f(PCM)\fcontrols\fthe\fturboch\brger\fv\bnes\fby\fme\bns\fof\f\bn\f
electronic\fv\bne\f\bdjustment\fsolenoid\f\btt\bched\fto\fthe\fturboch\brger.\f
Regul\btion\f\bt\fLow\fEngine\fSpeed\f
At\flow\fengine\fspeeds\fthe\fPCM\foper\btes\fthe\fv\bne\f\bdjustment\fsolenoid.\fThe\fv\bne\f\bdjustment\f
solenoid\fmoves\fthe\f\bdjusting\fring\fso\fth\bt\fthe\fv\bnes\f\bre\fset\f\bt\f\b\fsh\bllow\f\bngle.\fThe\fsh\bllow\f
int\bke\fcross\fsection\fthis\fcre\btes\ffor\fthe\fstre\bm\fof\fexh\bust\fg\bs\f\bllows\fthe\fturboch\brger\f
boost\fpressure\fto\fbuild\fup\fr\bpidly\f\bnd\fe\bsily\f\bt\flow\fengine\fspeeds.\f
Regul\btion\f\bt\fModer\bte\fEngine\fSpeed\f
As\fthe\fengine\fspeed\fincre\bses\f\bnd\fthe\fqu\bntity\fof\fexh\bust\fg\bs\fincre\bses,\fthe\fv\bne\f
\bdjustment\fsolenoid\fmoves\fthe\f\bdjusting\fring\fso\fth\bt\fthe\fv\bnes\f\bre\fset\f\bt\f\b\fsteeper\f\bngle.\f
The\fsteeper\f\bngle\fopens\fthe\fint\bke\fcross\fsection\feffectively\freducing\fthe\fg\bs\fflow\f\bnd\f
turbine\fspeed,\fwhile\fm\bint\bining\fconst\bnt\fturboch\brger\fboost\fpressure.\f
Regul\btion\f\bt\fM\bximum\fEngine\fSpeed\f
As\fthe\fengine\fspeed\fincre\bses\fthe\fint\bke\fcross\fsection\fin\ffront\fof\fthe\fturboch\brger\fturbine\f
is\fcontinuously\fenl\brged.\fThe\fturbine\fspeed\f\bnd\fhence\fthe\fqu\bntity\fof\fthe\f\bir\fsupplied\fto\f
the\fengine,\fis\f\bdjusted\fto\fsuit\fthe\fengine\fspeed.\fThis\fme\bns\fth\bt\fthe\fturboch\brger\fboost\f
pressure\frem\bins\foptimized\fover\f\bll\fengine\fspeeds.\f
The\fm\bximum\fposition\fof\fthe\fturboch\brger\fv\bnes\f(m\bximum\fopening\fcross\fsection)\fis\f\blso\f
\bn\femergency\fposition,\fin\fthe\fevent\fof\f\bn\felectric\bl\fconcern.\fThis\flowers\fthe\fch\bnce\fof\f
engine\fd\bm\bge\fdue\fto\fexcessive\fboost\fin\fthe\fevent\fof\f\b\fturboch\brger\fcontrol\fconcern.\f
Стр. 2 из 2
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Page 1583 of 4402

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 1.8L Dur\btorq-TDCi
(74kW/100PS) - Ly\fx/1.8L Dur\btorq-
TDCi (92kW/125PS) - Ly\fx -
Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Ge\fer\bl Equipme\ft
I\fspectio\f \b\fd Verific\btio\f
NO

TE:\fIt\fis\fnorm\bl\ffor\f\b\fsm\bll\f\bmount\fof\fcombustion\fg\b
s\fto\fp\bss\finto\fthe\fcr\bnkc\bse.\fThis\f
g\bs\fis\fsc\bvenged\finto\fthe\f\bir\fint\bke\fsystem\fthrough\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f
(PCV)\fsystem,\fwhich\fincorpor\btes\f\bn\foil\fsep\br\btor.\fSome\fengine\foil,\fin\fthe\fform\fof\f\b\f
v\bpor\fis\fc\brried\finto\fthe\f\bir\fint\bke\fsystem\fwith\fthe\fblow-by\fg\bses\f(this\fengine\foil\f\blso\f
contributes\fto\fv\blve\fse\bt\fdur\bbility).\fThis\fme\bns\fth\bt\foil\fwill\fcollect\finside\fthe\f\bir\fint\bke\f
components\f\bnd\fthe\fturboch\brger.\fThis\fis\fnot\f\bn\findic\btion\fth\bt\fthe\fturboch\brger\foil\fse\bl\f
h\bs\ff\biled.\fThe\fturboch\brger\foil\fse\bl\fwill\fnot\ff\bil\funless\fthe\fbe\brings\ff\bil\ffirst,\fwhich\fwill\f
c\buse\fthe\fturboch\brger\fto\fbecome\fnoisy\for\fseize.\fDo\fnot\finst\bll\f\b\fnew\fturboch\brger\fdue\f
to\foil\finside\fthe\fturboch\brger\for\fthe\f\bir\fint\bke\fcomponents.\fIf\f\b\fle\bk\fis\fdetected\fin\fthe\foil\f
supply\for\freturn\ftubes\for\fconnections,\floc\bte\f\bnd\frectify\fthe\fsource.\fDo\fnot\finst\bll\f\b\fnew\f
turboch\brger\fdue\fto\f\bn\foil\fle\bk.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

isu\bl I\fspectio\f Ch\brt
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
Symptom Ch\brt Symptom Ch\brt
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b
Oil\fle\bk(s)\f\f
Air\fcle\bner\felement\f\f
Air\fcle\bner\foutlet\fpipe\f\f
Air\fcle\bner\fint\bke\fpipe\f\f
Turboch\brger\foil\fsupply\fpipe\f\f
Turboch\brger\foil\freturn\ftube\f\f
Turboch\brger\fint\bke\fpipe\f\f
Turboch\brger\fhousing\f\f
Ch\brge\f\bir\fcooler\f\f
Ch\brge\f\bir\fcooler\fint\bke\fpipe\f\bnd\fhose(s)\f\f
Ch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fhose(s)\fWiring\fh\brness\f\f
Turboch\brger\felectronic\f\bctu\btor\f\f
PCM\f
\fymptomPossib\be \fourcesAction
Blue\fsmoke\fwith\f
excessive\f
turboch\brger\fnoiseTurboch\brger\f
compressor\frubbing\fon\f
housing\fw\blls.\f Turboch\brger\fturbine\f
rubbing\fon\fhousing\f
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Стр. 1 из 5
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Page 1584 of 4402

$FORD GALAXY 2006 Service Repair Manual Pi\fpoi\ft Tests w\blls.\fTurboch\brger\fbe\brings\f \bnd\foil\fse\bl(s).\f Turboch\brger\foil\f supply\ftube\fblocked\for\f d\bm\bged.\f * * Blue\fsmoke\fwithout\f excessive\f turboch\brger\fnoiseTu$

Page 1586 of 4402

$FORD GALAXY 2006 Service Repair Manual \bir\fnozzle,\fcheck\fthe\foil\fsupply\ftube\ffor\fblock\bge.\f Is\fthe\foil\fsupply\ftube\ffree\ffrom\fblock\bge?\f Yes GO\fto\fA5.\f\f No I NSTALL\f\b\fnew\fturboch\brger\f\bnd\fturboch\brger\foil$

Page 1591 of 4402

$FORD GALAXY 2006 Service Repair Manual Fuel Ch\brgi\fg \b\fd Co\ftrols - Turboch\brger - 2.0L Dur\btorq-TDCi (85kW/115PS) - DW/2.0L Dur\btorq-TDCi (100kW/136PS) - DW/2.0L Dur\btorq- TDCi (103kW/140PS) - DW, Emissio\f Requireme\fts: St\$

Page 1592 of 4402

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L Dur\btorq-TDCi
(85kW/115PS) - DW/2.0L Dur\btorq-TDCi
(100kW/136PS) - DW/2.0L Dur\btorq-
TDCi (103kW/140PS) - DW, Emissio\f
Requireme\fts: St\bge IV - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Speci\bl Tool(s)
Ge\f

er\bl Equipme\ft
I\fspectio\f \b\fd Verific\btio\f
N O

TE:\fIt\fis\fnorm\bl\ffor\f\b\fsm\bll\f\bmount\fof\fcombustion\fg\b
s\fto\fp\bss\finto\fthe\fcr\bnkc\bse.\fThis\f
g\bs\fis\fsc\bvenged\finto\fthe\f\bir\fint\bke\fsystem\fthrough\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f
(PCV)\fsystem,\fwhich\fincorpor\btes\f\bn\foil\fsep\br\btor.\fSome\fengine\foil,\fin\fthe\fform\fof\f\b\f
v\bpor\fis\fc\brried\finto\fthe\f\bir\fint\bke\fsystem\fwith\fthe\fblow-by\fg\bses\f(this\fengine\foil\f\blso\f
contributes\fto\fv\blve\fse\bt\fdur\bbility).\fThis\fme\bns\fth\bt\foil\fwill\fcollect\finside\fthe\f\bir\fint\bke\f
components\f\bnd\fthe\fturboch\brger.\fThis\fis\fnot\f\bn\findic\btion\fth\bt\fthe\fturboch\brger\foil\fse\bl\f
h\bs\ff\biled.\fThe\fturboch\brger\foil\fse\bl\fwill\fnot\ff\bil\funless\fthe\fbe\brings\ff\bil\ffirst,\fwhich\fwill\f
c\buse\fthe\fturboch\brger\fto\fbecome\fnoisy\for\fseize.\fDo\fnot\finst\bll\f\b\fnew\fturboch\brger\fdue\f
to\foil\finside\fthe\fturboch\brger\for\fthe\f\bir\fint\bke\fcomponents.\fIf\f\b\fle\bk\fis\fdetected\fin\fthe\foil\f
supply\for\freturn\ftubes\for\fconnections,\floc\bte\f\bnd\frectify\fthe\fsource.\fDo\fnot\finst\bll\f\b\fnew\f
turboch\brger\fdue\fto\f\bn\foil\fle\bk.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

isu\bl I\fspectio\f Ch\brt
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
H\bnd\fV\bcuum/Pressure\fPump\f
416\f-\fD001\f(23\f-\f036A)\f
Fuel\fPressure\fG\buge\f
310-053\f(23-046)\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)\f(418-
F224)
Mechanica\bE\bectrica\b

Oil\fle\bk(s)\f\f
Air\fcle\bner\felement\f\f
Air\fcle\bner\foutlet\fpipe\f\f
Air\fcle\bner\fint\bke\fpipe\f\f
Turboch\brger\foil\fsupply\for\foil\freturn\ftube\f\f
Turboch\brger\fint\bke\fpipe\f\f
Turboch\brger\fv\bcuum\fdi\bphr\bgm\funit\f\f
Turboch\brger\fhousing\f\f
Ch\brge\f\bir\fcooler\f\f
Ch\brge\f\bir\fcooler\fint\bke\fpipe\f\bnd\fhose(s)\f\f
Ch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fhose(s)\fWiring\fh\brness\f\f
V\bne\f\bdjustment\fsolenoid\fv\blve\f\f
PCM\f
\f
\f\f
Стр. 1 из 11
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Page 1593 of 4402

$FORD GALAXY 2006 Service Repair Manual (if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f 4. 4. If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f C h\brt.\f Symptom Ch\brt Sympt$

(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
Symptom Ch\brt Symptom Ch\brt
Pi\fpoi\ft Tests N O
TE:\fThe\fv\bcuum\fdi\bphr\bgm\funit\fis\f\b\ffixed\fp\brt\fof\fth
e
\fturboch\brger\f\bnd\fc\bnnot\fbe\f
\bdjusted\for\frenewed.\f
\fymptomPossib\be \fourcesAction
Blue\fsmoke\fwith\f
excessive\f
turboch\brger\f
noiseTurboch\brger\f
compressor\frubbing\f
on\fhousing\fw\blls.\f
Turboch\brger\f
turbine\frubbing\fon\f
housing\fw\blls.\f Turboch\brger\f
be\brings\f\bnd\foil\fse\bl
(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\f
or\fd\bm\bged.\f
*
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Blue\fsmoke\f
without\fexcessive\f
turboch\brger\f
noise
Turboch\brger\foil\f
return\ftube\fblocked\f
or\fd\bm\bged.\f
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
Poor\fengine\f
perform\bnce\fV\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline(s).\f
*CHECK\f\bll\fv\bcuum\fline(s)\f\bre\finst\blled\f\bnd\fno\f
signs\fof\f\bir\fle\bks\f\bre\fpresent.\fREPAIR\f\bs\f
necess\bry.\f
*
Ch\brge\f\bir\fcooler\f
system.\f
*CHECK\fthe\fch\brge\f\bir\fcooler,\fch\brge\f\bir\fcooler\f
pipes\f\bnd\fch\brge\f\bir\fcooler\fhoses\ffor\fle\bks\f\bnd\f
obstructions.\fREPAIR\f\bs\fnecess\bry.\f
*
Air\fcle\bner\fint\bke\f
pipe.\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\fobstruction.\f
REPAIR\fthe\fnecess\bry.\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
v\bcuum\fdi\bphr\bgm\f
unit\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fv\bcuum\fdi\bphr\bgm\funit\f\bctu\btor\frod\fh\bs\f
not\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\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\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
V\bcuum\fdi\bphr\bgm\f
unit\f\bctu\btor\frod.\f
*CHECK\fthe\fv\bcuum\fdi\bphr\bgm\funit\f\bctu\btor\frod\f
moves\ffreely,\fIf\fthe\fv\bcuum\fdi\bphr\bgm\funit\f
\bctu\btor\frod\fdoes\fnot\fmove\ffreely.\fCHECK\ffor\f
signs\fof\fd\bm\bge\for\fsigns\fof\fforeign\fm\bteri\bl.\f
REPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure.\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
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