Page 1031 of 4402
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
Стр. 8 из
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Page 1032 of 4402

18.18.
Inst\bll\fthe\fglow\fplugs.\f
1
9. 19.
Inst\bll\fthe\fglow\fplug\fpower\fsupply.\f
2
0. \b0.
Inst\bll\fthe\fEGR\fv\blve.\f\f
R
EFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve \f(303-
08D\fEngine\fEmission\fControl\f
-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
21. \b1.
Inst\bll\fthe\fEGR\fcooler.\fREFER\fto:\f E
xh\bust\fG\bs\fRecircul\btion\f(EGR)\fCooler\f(303-
08C
\fEngine\fEmission\fControl\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
22. \b\b.
Connect\fthe\ffuel\finjector\felectric\bl\fconnectors.\f
2
3. \b3.
Apply\fso\bp\fsolution\fto\fthe\fb\bll\fclip\fmountings\fin\fthe\fengine\fupper\fcover.\f
S
o\bp\fsolution\f(m\bximum\fconcentr\btion\fof\fso\bp\fin\fw\bter\f1:200).\f \f
\f
\f\f
\f\f
Стр. 9 из 13
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Page 1033 of 4402

24.CAUTION:\fCont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\f
d\b
m\bge\f(scr\btches)\fon\fthe\fengine\fupper\fcover.\fF\bilure\fto\ffollow\fthis\finstruction\f
m\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
\b4. Put\fthe\fengine\fcover\finto\finst\bll\btion\fposition\f\bnd\fclip\fit\fin\fpl\bce\fby\fpressing\f\bt\f
th
e\fpl\bces\fshown.\f
M\bke\fsure\fth\bt\fthe\fengine\fupper\fcover\fis\ffully\feng\bged\fin\fthe\f\bre\b\fof\fthe\ffuel\ffilter,\f
if\fnecess\bry\f\bpply\fmore\fpressure\fin\fthe\f\bre\bs\fshown.\f
25. \b5.
Inst\bll\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
Ins
t\bll\btion).\f
26. \b6.
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
27. \b7.
Inst\bll\fthe\fglow\fplug\frel\by.\f
2
8. \b8.
Inst\bll\fthe\fr\bdi\btor\fundershield.\f
\f\f
\f\f
\f\f
Стр. 10 из 13
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Page 1150 of 4402

cr\bnkSt\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\fREFER\fto:\f
St\brting\fSystem \f(303-06E\fSt\brting\f
Sys
tem\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
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brtFuel\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(310-01D\fFuel\fT\bnk\f\bnd\fLines\f-
\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\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
3-07E\fGlow\fPlug\fSystem\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\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.\f
REFER\fto:\f Timing\fBelt \f(303-01G\fEngine\f-\f
2.2
L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Broken\for\fd\bm\bged\ftiming\f
belt/timing\fch\bin\for\f
pulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\fREFER\fto:\f
Timing\fBelt \f(303-01G\fEngine\f-\f2.2L\f
Dur
\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\frough.Fuel\fch\brging\fsystem.\f
*CHECK\fthe\ffuel\fch\brging\fsystem.\fREFER\f
to:\f Fuel\fCh\brging\f\bnd\fControls\f(303-04F\f
Fue
l\fCh\brging\f\bnd\fControls\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\fREFER\fto:\f
Int\bke\fAir\fDistribution\f\bnd\fFiltering \f(303-
12F
\fInt\bke\fAir\fDistribution\f\bnd\fFiltering\f-\f
2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-
\fDW,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Exh\bust\fsystem\fblocked.\f
*CHECK\fthe\fexh\bust\fsystem.\fREFER\fto:\f
Exh\bust\fSystem\f(309-00F\fExh\bust\f
Sys
tem\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fDescription\f\bnd\f
Oper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\fREFER\fto:\f
Turboch\brger \f(303-
04K\fFuel\fCh\brging\f\bnd\f
Controls\f-\fTurboch\brger\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-
\fDW,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\fsprocket\f
or\fpulley/sprocket\f
d\bm\bged.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
Timing\fBelt \f(303-01G\fEngine\f-\f2.2L\f
Du r
\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Стр. 3 из
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Page 1153 of 4402

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
Ins
t\bll\btion).\f
8. NOTE:\fThe\fengine\fupper\fcover\fis\fheld\fin\fpl\bce\fby\f3\fb\bll\fclips.\fThe\fb\bll\fclips\f\bre\fnot\f
ve
rtic\bl,\fbut\f\bre\f\bngled\fb\bckw\brds\fby\f\bpproxim\btely\f20\fdegrees.\f
8. Loc\btion\fof\fthe\fengine\fupper\fcover\fb\bll\fclips.\f\f
9. CAUTION:\fCont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\f
d \b
m\bge\f(scr\btches)\fon\fthe\fengine\fupper\fcover.\fIf\fthe\f\bmbient\ftemper\bture\fis\fbelow\f
0°C,\fdet\bch\fthe\fengine\fupper\fcover\fwith\fextreme\fc\bution.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\fcover\fin\fthe\fsequence\fshown.\f
9. Remove\fthe\fengine\fupper\fcover.\f
Det\bch\fthe\fengine\fupper\fcover\fb\bll\fclips\fin\fthe\fsequence\fshown.\f
\f\f
\f\f
\f\f
Стр. 6 из 12
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Page 1154 of 4402
10.CAUTION:\fDo\fnot\fdisconnect\fthe\ffuel\finjection\fpump\felectric\bl\fconnectors\f\bnd\f
cr
\bnk\fthe\fengine.\f
10. Disconnect\fthe\ffuel\finjector\felectric\bl\fconnectors.\f
11. 11.
Remove\fthe\fexh\bust\fg\bs\frecircul\btion\f(EGR)\fcooler.\fREFER\fto:\f E
xh\bust\fG\bs\f
Rec
ircul\btion\f(EGR)\fCooler \f(303-08E\fEngine\fEmission\fControl\f-\f2.2L\fDur\btorq-TDCi
\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
12. 1\b.
Remove\fthe\fEGR\fv\blve.\fREFER\fto:\f E
xh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve\f(303-
08E
\fEngine\fEmission\fControl\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\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
\f\f
\f\f
\f\f
Стр. 7 из 12
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Page 1155 of 4402

15.15.
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
1
8. 18.
Inst\bll\fthe\fglow\fplugs.\f
1
9. 19.
Inst\bll\fthe\fglow\fplug\fpower\fsupply.\f
2
0. \b0.
Inst\bll\fthe\fEGR\fv\blve.\f\f
R
EFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve \f(303-08E\fEngine\fEmission\fControl\f
-\f2
.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
21. \b1.
Inst\bll\fthe\fEGR\fcooler.\f\f
R
EFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fCooler \f(303-08E\fEngine\fEmission\f
Con
trol\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f \f\f
\f\f
\f\f
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Page 1156 of 4402

22.\b\b.
Connect\fthe\ffuel\finjector\felectric\bl\fconnectors.\f
2
3. \b3.
Apply\fso\bp\fsolution\fto\fthe\fb\bll\fclip\fmountings\fin\fthe\fengine\fupper\fcover.\f
S
o\bp\fsolution\f(m\bximum\fconcentr\btion\fof\fso\bp\fin\fw\bter\f1:200).\f
24
. CAUTION:\fCont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\f
d\b
m\bge\f(scr\btches)\fon\fthe\fengine\fupper\fcover.\fF\bilure\fto\ffollow\fthis\finstruction\f
m\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
\b4. Put\fthe\fengine\fcover\finto\finst\bll\btion\fposition\f\bnd\fclip\fit\fin\fpl\bce\fby\fpressing\f\bt\f
t h
e\fpl\bces\fshown.\f
M\bke\fsure\fth\bt\fthe\fengine\fupper\fcover\fis\ffully\feng\bged\fin\fthe\f\bre\b\fof\fthe\ffuel\ffilter,\f
if\fnecess\bry\f\bpply\fmore\fpressure\fin\fthe\f\bre\bs\fshown.\f
25. \b5.
Inst\bll\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
Ins
t\bll\btion).\f
26. \b6.
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
27. \b7.
Inst\bll\fthe\fglow\fplug\frel\by.\f
\f\f
\f\f
\f\f
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