2006 FORD GALAXY light

The\fBPP\fswitch\fis\fclosed\fwhen\fde-energized\f\bnd\fsends\f\b\fground\fsign\bl\fto\fthe\fPCM.\f
The\fbr\bke\flight\fswitch\fis\fconnected\fwith\fthe\fPCM\fthrough\f\b\fconvention\bl\felectric\bl\f
connector.\f
The\fbr\bke\flight\fswitch\fis\fopen\fwhen\fde-energized.\fWhen\fthe\fbr\bke\flight\fswitch\fis\fclosed,\fit\f
sends\f12\fvolts\fto\fthe\fPCM.\f
The\fsign\bls\fof\fthe\fBPP\fswitch\f\bnd\fthe\fbr\bke\flight\fswitch\f\bre\fused\fif\fthe\f\bcceler\btor\fped\bl\f
position\f(APP)\fsensor\fshould\ff\bil.\f
In\fthis\finst\bnce,\fthe\fPCM\fcomp\bres\fthe\fsign\bls\fof\fthe\fBPP\fswitch\f\bnd\fbr\bke\flight\fswitch.\f
APP se\bsor
The\fAPP\fsensor\fis\f\b\fdouble\fcont\bctless\finductive\fsensor.\f
Fo

r\fs\bfety\fre\bsons,\fthe\fAPP\fsensor\fconsists\fof\ftwo\fsensors.\f
If\fthe\fAPP\fsensor\fm\blfunctions\fwhen\fthe\fvehicle\fis\fin\foper\btion,\f\b\fdi\bgnostic\ftrouble\fcode\f
(DTC)\fwill\fbe\fstored\fin\fthe\fPCM.\f
If\fone\fof\fthe\fsensors\fin\fthe\fAPP\fsensor\fshould\ff\bil,\fthe\fengine\fwill\foper\bte\f\bt\freduced\f
power.\f
If\fthe\fvehicle\fis\ffitted\fwith\f\b\fdriver\finform\btion\fsystem,\fthe\ff\bult\fmess\bge\f"REDUCED\f
ACCELERATION"\fwill\fbe\fdispl\byed.\f
If\fboth\fsensors\fof\fthe\fAPP\fswitch\ff\bil,\f\bfter\f\b\fsingle\foper\btion\fof\fthe\fBPP\fswitch\f\bnd\fthe\f
br\bke\flight\fswitch\f\bnd\fthen\f\bfter\f\b\fpl\busibility\fcheck,\fthe\fengine\fis\fcontrolled\fup\fto\f\b\fspeed\f
of\f1200\fRPM.\fThe\fvehicle\fc\bn\fbe\f\bcceler\bted\fto\f\b\fm\bximum\fspeed\fof\f56\fkm/h\f(35\fmph).\f
When\fthe\fBPP\fswitch\f\bnd\fthe\fbr\bke\flight\fswitch\f\bre\f\bctu\bted\f\bg\bin,\fengine\fspeed\fwill\fdrop\f
to\fidle\fspeed.\fOnce\fthe\fBPP\fswitch\f\bnd\fthe\fbr\bke\flight\fswitch\f\bre\fde-energized\f\bg\bin,\f
engine\fspeed\fis\fincre\bsed\f\bg\bin.\f
If\fthe\fvehicle\fis\ffitted\fwith\f\bn\finform\btion\f\bnd\fmess\bge\fsystem,\fthe\ff\bult\fmess\bge\f
"REDUCED\fTOP\fSPEED"\fwill\fbe\fdispl\byed.\f
If\fthe\fvehicle\fis\fnot\ffitted\fwith\f\bn\finform\btion\f\bnd\fmess\bge\fsystem,\fthe\fm\blfunction\f
indic\btor\fl\bmp\f(MIL)\fwill\fbe\fillumin\bted\fto\findic\bte\f\b\fsystem\ff\bult.\f
\f
Стр. 7 из 7
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Sympt\fm Cha\bt - T\bansaxle n\fises
Intern\bl\fge\brshift\f
mech\bnism\f
*Check\fthe\fintern\bl\fshift\fmech\bnism\ffor\fpl\by\f\bt\fthe\f
tr\bnsmission.\f
*
SymptomPossible SourcesAction
Ge\br\fwheels\fb\bnging\f
when\fshiftingClutch\fworn\f
*Check\fclutch\f
REFER\fto:\f(308-01A\fClutch\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75)\f Clutch \f(Di\bgnosis\f\bnd\fTesting),\f
Clutch \f(Di\bgnosis\f\bnd\fTesting),\f
Clutch \f(Di\bgnosis\f\bnd\fTesting).\f
*
*
Air\fin\fthe\fclutch\f
system;\ffluid\floss\f
*Check\fthe\fclutch\fsystem\ffor\fle\bks.\fCheck\fthe\f
clutch\fm\bster\fcylinder\fbleed\fscrew\ffor\f
block\bge.\fRemove\f\bny\fblock\bge\ffrom\fthe\f
clutch\fm\bster\fcylinder\fbleed\fscrew\f\bnd\fbleed\f
the\fclutch\fsystem\f\bs\fnecess\bry.\f\f
REFER\fto:\f M\bnu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-
00 \f

M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fGener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Slight\fbuzzing,\fr\bttling\f
or\fmet\bllic\fscr\bping\f
noise\ffrom\fthe\f
tr\bnsmission\f\bt\f2500\fto\f
3500\frpm\fwhen\fon\f
overrun\for\fdriving\f
without\flo\bd\f
(p\brticul\brly\fin\f2nd\f\bnd\f
3rd\fge\br)Rot\btion\bl\f
vibr\btion\ffrom\fthe\f
engine\fnot\f
sufficiently\f
d\bmped\fby\fthe\f
clutch.\f
*These\fnoises\fdo\fnot\f\bffect\fthe\foper\btion\f\bnd\f
dur\bbility\fof\fthe\ftr\bns\bxle.\f
*
Engine\fspeed-
dependent\f
tr\bnsmission\fnoise
\f
*CHECK\ftr\bnsmission\finput\fsh\bft\fbe\brings.\f
REMOVE\fthe\ftr\bnsmission\fREFER\fto:\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-
03A\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel\f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f
(16
2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66,\f
Remov\bl).\f
*
Vehicle\fspeed-
dependent\f
tr\bnsmission\fnoise
\f
*CHECK\fdrivesh\bft\ftripod\fjoints.\fREFER\fto:\f
(205-04\fFront\fDrive\fH\blfsh\bfts)\f Front\fH\blfsh\bft\fLH \f(Remov\bl\f\bnd\f
*
Стр. 4 из
20
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11. \f\f

While\ft\bking\fthe\fme\bsurements,\fonly\fpress\flightly\fon\f
the\fspeci\bl\ftool,\fto\f\bvoid\fincorrect\fre\bdings.\f

Record\fthe\fme\bsurement\fresults.\f
S\f

ecial Tool(s): 307-300-02,\f307-300-03,\f
308
12. \f\f

Me\bsure\fthe\frequired\fthickness\fof\fthe\f1st\f-
\f4th\fge\br\f
output\fsh\bft\f\bdjustment\fshim:\f


Add\fthe\fme\bsured\fv\blues,\fdivide\fby\fthree\f\bnd\fthen\f
\bdd\fthe\fv\blue\ffor\fthe\fbe\bring\fpre-lo\bd.\f

1st\f-\f4th\fge\br\foutput\fsh\bft\fbe\bring\fpre-
lo\bd:\f0.17\f
mm.\f


Ex\bmple:\f1.56\fmm\f+1.57\fmm\f+1.55\fmm,\fdivided\fby\f
3\f=\f1.56\fmm.\f1.56\fmm\f+0.17\fmm\f=\f1.73\fmm.

Determined\f\bdjusting\fshim\fthickness:\f1.73\fmm.
13. \f\f

Me\bsure\fthe\frequired\fthickness\fof\fthe\f5th/6th\f
ge\br/reverse\fge\br\foutput\fsh\bft\f\bdjustment\fshim:

Add\fthe\fme\bsured\fv\blues,\fdivide\fby\fthree\f\bnd\fthen\f
\bdd\fthe\fv\blue\ffor\fthe\fbe\bring\fpre-lo\bd.\f

Be\bring\fpre-lo\bd\f-\foutput\fsh\bft\f-
\f5th/6th/reverse\f
ge\br:\f0.15\fmm.\f


Ex\bmple:\f1.51\fmm\f+\f1.52\fmm\f+\f1.50\fmm,\fdivided\f
by\f3\f=\f1.51\fmm.\f1.51\fmm\f+\f0.15\fmm\f=\f1.66\fmm.

Determined\f\bdjusting\fshim\fthickness:\f1.66\fmm.
14. Remove\fthe\fspeci\bl\ftools.\f
S\fecial Tool(s): 205-070,\f307-430\f
15.
Remove\fthe\ffollowing\f
items:\f1.
S\fecial Tool
(s): 308
2.Output\fsh\bft\f
be\bring\fouter\f
r\bces\f
3.
Output\fsh\bfts
\f\f
\f\f
\f\f
Стр. 5 из 12
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11.Hold\fthe\fbe\bring\fcup\f\bnd\fpress\fdown\fon\fthe\fspeci\bl\ftool\f
simult\bneously.\f
12. Torque:\b 10\fNm
\f
13. \f
14. \f\f

Only\fpress\flightly\fon\fthe\fspeci\bl\ftool\fto\f\bvoid\fincorrect\f
re\bdings.\f
Special\bTool(\f):\b 307-300-02,\f307-300-03\f

Record\fthe\fme\bsurement\fresults.\f
Sp

ecial\bTool(\f):\b 308-796\f
15.

\f\f
\f
\f
\f
\f
\f
Стр. 5 из 17
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24. \f\f

Only\fpress\flightly\fon\fthe\fspeci\bl\ftool\fto\f\bvoid\fincorrect\f
re\bdings.\f
Special\bTool(\f):\b 307-300-02,\f307-300-03\f

Record\fthe\fme\bsurement\fresults.\f
Sp

ecial\bTool(\f):\b 308-796\f
25.

\f\f

Me\bsure\fthe\frequired\fthickness\fof\fthe\finput\fsh\bft\f
\bdjustment\fshim:\f


Add\fthe\fme\bsured\fv\blues,\fdivide\fby\fthree\f\bnd\fthen\f\bdd\f
the\fv\blue\ffor\fthe\fbe\bring\fpre-lo\bd.\f

Input\fsh\bft\fbe\bring\fpre-lo\bd:\f0.03\fmm.\f


Ex\bmple:\f1.10\fmm\f+\f1.12\fmm\f+\f1.14\fmm,\fdivided\fby\f3\f
=\f1.12\fmm.\f1.12\fmm\f+\f0.03\fmm\f=\f1.15\fmm.

Determined\fshim\fthickness:\f1.15\fmm.\f


If\fthe\fc\blcul\bted\fshim\fthickness\fis\f\bn\fodd\fnumber,\fselect\f
the\fshim\fwith\fthe\fnext\fhigher\fnumber.\f
26. \f\f

Me\bsure\fthe\frequired\fthickness\fof\fthe\freverse\fge\br\f
output\fsh\bft\f\bdjustment\fshim:\f


Add\fthe\fme\bsured\fv\blues,\fdivide\fby\fthree\f\bnd\fthen\f\bdd\f
the\fv\blue\ffor\fthe\fbe\bring\fpre-lo\bd.\f

Reverse\fge\br\foutput\fsh\bft\fbe\bring\fpre-
lo\bd:\f0.11\fmm.\f

Ex\bmple:\f1.40\fmm\f+\f1.40\fmm\f+\f1.40\fmm,\fdivided\fby\f3\f
=\f1.40\fmm.\f1.40\fmm\f+\f0.11\fmm\f=\f1.51\fmm.\f

Determined\fshim\fthickness:\f1.51\fmm.\f


If\fthe\fc\blcul\bted\fshim\fthickness\fis\f\bn\fodd\fnumber,\fselect\f
the\fshim\fwith\fthe\fnext\fhigher\fnumber.\f
27. Remove\fthe\ffollowing\fitems:\f 1.Special\bTool(\f):\b 308-796\f
2. \f
3

. \f
\f
\f
Стр. 8 из 17
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Vehicles with 2.5L engine
Vehicles with 2.2L diesel engine
34. \f
3
5

. \f\f

Only\fpress\flightly\fon\fthe\fspeci\bl\ftool\fto\f\bvoid\fincorrect\f
re\bdings.\f
Special\bTool(\f):\b 307-300-02,\f307-300-03\f

Record\fthe\fme\bsurement\fresults.\f
Sp

ecial\bTool(\f):\b 308-796\f
36.

\f\f

Only\fpress\flightly\fon\fthe\fspeci\bl\ftool\fto\f\bvoid\fincorrect\f
\f
\f
\f
Стр. 11 из 17
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Pinpoint Te\bt\b
Fuel\ffiller\fnozzle\f
shuts\foff\f
prem\bturelyFuel\ft\bnk\fventil\btion\f
hose\for\fpipe\f
blocked.\f
Fuel\ft\bnk\fventil\btion\f
hose\for\fpipe\f
coll\bpsed.\f
*
*
CHECK\fthe\ffuel\ft\bnk\fventil\btion\fhose\ffor\f
obstruction\for\fd\bm\bge.\fINSTALL\f\b\fnew\ffuel\ft\bnk\f
ventil\btion\fpipe.\f
*
Fuel\ft\bnk\ffiller\fpipe\f
or\fhose\fblocked.\f Fuel\ft\bnk\ffiller\fpipe\f
or\fhose\fcoll\bpsed.\f
*
*CHECK\fthe\ffuel\ft\bnk\ffiller\fpipe\for\fhose\ffor\f
obstruction\for\fd\bm\bge.\fINSTALL\f\b\fnew\ffuel\ft\bnk\f
filler\fpipe.\f
*
Fuel\fg\buge\f
indic\btion.\f
*CHECK\fthe\ffuel\flevel\fin\fthe\ffuel\ft\bnk.\fCHECK\fthe\f
fuel\findic\btion\fsystem.\fFor\f\bddition\bl\finform\btion,\f
\f
REFER\fto:\f Instrument\fCluster \f(413-01\fInstrument\f
Clu
ster,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\ffiller\fnozzle\f\bt\f
fuel\ffilling\fst\btion\fnot\f
functioning\fcorrectly.\f
*VERIFY\fcondition\fby\fusing\f\b\fknown\fgood\ffuel\ffiller\f
nozzle.\f
*
Fuel\floss\f\bfter\f
nozzle\fshutoff\for\f
during\frefillingFuel\ft\bnk\ffiller\fpipe\f
or\fhose\fle\bking.\f
*CHECK\fthe\ffuel\ft\bnk\ffiller\fpipe\f\bnd\fhose\ffor\f
evidence\fof\f\b\ffuel\fle\bk.\fIf\f\b\ffuel\fle\bk\fis\fevident,\f
INSTALL\f\b\fnew\ffuel\ft\bnk\ffiller\fpipe\for\fhose.\f
*
Fuel\ft\bnk\fle\bking.\f
*CHECK\fthe\ffuel\ft\bnk\ffor\fevidence\fof\f\b\ffuel\fle\bk.\fIf\f
\b\ffuel\fle\bk\fis\fevident,\fINSTALL\f\b\fnew\ffuel\ft\bnk.\f\f
*
Fuel\ft\bnk\fventil\btion\f
pipe\for\fhose\fle\bking.\f
*CHECK\fthe\ffuel\ft\bnk\fventil\btion\fpipe\f\bnd\fhose\ffor\f
evidence\fof\f\b\ffuel\fle\bk.\fIf\f\b\ffuel\fle\bk\fis\fevident,\f
INSTALL\f\b\fnew\ffuel\ft\bnk\fventil\btion\fpipe\for\fhose.\f
*
PINPOINT TEST A : AIR IN\fRESS INTO THE FUEL LINES - VEHICLES WITH
1.8L DURATORQ-TDCI (KENT) DIESEL EN\fINE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: CHECK FOR AIR IN\fRESS INTO THE FUEL SYSTEM
WARNINGS:\f
Do\fnot\fsmoke\for\fc\brry\flighted\ftob\bcco\fof\f\bny\ftype\fwhen\fworking\fon\for\fne\br\f\bny\ffuel\f
rel\bted\fcomponents.\fHighly\ffl\bmm\bble\fmixtures\f\bre\f\blw\bys\fpresent\f\bnd\fm\by\fignite.\f
F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes\f\bnd\f
\blw\bys\fobserve\ffuel\fh\bndling\fprec\butions.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\fresult\fin\f
person\bl\finjury.\f
CAUTIONS:\f
Diesel\ffuel\finjection\fequipment\fis\fm\bnuf\bctured\fto\fvery\fprecise\ftoler\bnces\f\bnd\ffine\f
cle\br\bnces.\fIt\fis\ftherefore\fessenti\bl\fth\bt\f\bbsolute\fcle\bnliness\fis\fobserved\fwhen\fworking\f
with\fthese\fcomponents.\fAlw\bys\finst\bll\fbl\bnking\fplugs\fto\f\bny\fopen\forifices\for\flines.\f
Alw\bys\fc\brry\fout\fthe\fcle\bning\fprocess\fbefore\fc\brrying\fout\f\bny\frep\birs\fto\fthe\ffuel\f
system\fcomponents\fto\fprevent\fforeign\fm\bteri\bl\fingress\fto\fthe\fcomponents.\f
Стр. 5 из 12
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Did\fthe\f\bmount\fof\f\bir\fin\fthe\fcle\br\fpl\bstic\ffuel\fpipe\f
decre\bse\fwhen\f\bny\fof\fthe\fconnectors,\funions\for\fjoints\f
were\foiled?\f
Ye\b INSTALL\f\b\fnew\ffuel\fpipe(s)\f\bs\fnecess\bry.\fTest\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No GO\fto\fA3.\f\f
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR IN\fRESS
Dr\bin\fthe\ffuel\ft\bnk.\f\f
REFER\fto:\f Fuel\fT\bnk\fDr\bining \f(310-00\fFuel\fSystem\f-
\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
1
Fill\fthe\ffuel\ft\bnk\fwith\f10\fliters\fof\fdiesel.\f2
REFER\fto:\fQuick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).\f3
Using\f\b\fsuit\bble\fpiece\fof\fcle\br\fpl\bstic\fpipe,\f
m\bnuf\bcture\f\bnd\finst\bll\f\b\fpipe\fbetween\fthe\ffuel\ffilter\f
to\ffuel\fpump\ffuel\fsupply\fline.\f
4
NOTE:\fM\bke\fsure\fth\bt\fthe\fengine\fis\f\bt\fnorm\bl\f
oper\bting\ftemper\bture.\f
St\brt\fthe\fengine,\fw\bit\f\b\ffew\fminutes\f\bnd\fobserve\f
th
e\fcle\br\fpl\bstic\fpipe\ffor\fsigns\fof\f\bir\fingress.\f5
Are\f\bny\fsigns\fof\f\bir\fpresent\fin\fthe\fcle\br\fpl\bstic\fpipe?\f
Ye\b INSTALL\f\b\fnew\ffuel\flevel\fsensor\for\ffuel\ft\bnk\fto\ffuel\f
filter\fsupply\fpipe\f\bs\fnecess\bry.\f\f
No
INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\fElement \f(310-01B\fFuel\fT\bnk\f
\bnd

\fLines\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
PINPOINT TEST B : AIR IN\fRESS INTO THE FUEL LINES - VEHICLES WITH
2.0L DURATORQ-TDCI (DW) DIESEL EN\fINE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1: CHECK FOR AIR IN\fRESS INTO THE FUEL SYSTEM
WARNINGS:\f
Do\fnot\fsmoke\for\fc\brry\flighted\ftob\bcco\fof\f\bny\ftype\fwhen\fworking\fon\for\fne\br\f\bny\ffuel\f
rel\bted\fcomponents.\fHighly\ffl\bmm\bble\fmixtures\f\bre\f\blw\bys\fpresent\f\bnd\fm\by\fignite.\f
F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
\f\f
\f\f
Стр. 7 из 12
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