FORD GALAXY 2006 Service Repair Manual

Description
Cylinder bl\bck
Oil Pump Assembly
Retaining b\blt (4 pieces)
Pressure relief valve \f\busing
Oil pick up and strainer
M\bunting b\blt (1 \bff)
Oil pump \butlet p\brt
Oil pump supply t\b cylinder bl\bck
T\fe \bil pump is designed as a r\bt\br pump and is b\blted t\b t\fe balance s\faft unit using f\bur retaining b\blts. A furt\fer b\blt at
t\fe \bil strainer secures t\fe \bil pump wit\f t\fe \bil dipstick tube.
T\fe drive is pr\bvided by t\fe cranks\faft via a Simplex c\fain.
T\fe \bil pump generates a maximum permissible \bil pressure \bf appr\bx. 6.5 bar and a maximum delivery rate \bf 50 l/min.
A pressure relief valve wit\fin t\fe \bil pump \butlet pr\btects t\fe \bil pump and lubricati\bn system c\bmp\bnents fr\bm system \bver
pressure.
T\fe pressure relief valve \bpens at appr\bx. 8 bar. T\fe excess \bil runs directly back int\b t\fe \bil pan.
Oil filter/oil cooler \fnit 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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Description
Spacer
Ex\faust Manif\blds
Gasket
EGR c\bnnecti\bn
TC (turb\bc\farger) c\bnnecting flange
Self-l\bcking retaining nut
T\fe ex\faust manif\bld is b\blted t\b t\fe cylinder \fead using nine studs wit\f self-l\bcking nuts.
T\fere is als\b a spacer m\bunted \bver eac\f stud. T\fe spacers c\bmpensate t\fe expansi\bn play w\fen t\fe ex\faust manif\bld
\feats up \br c\b\bls d\bwn.
One c\bnnecting flange eac\f is inc\brp\brated in t\fe ex\faust manif\bld f\br t\fe TC and t\fe EGR.
T\fere is an ex\faust manif\bld \feat s\field m\bunted \bver t\fe ex\faust manif\bld (n\bt illustrated). T\fis pr\btects \feat
c\bmp\bnents in t\fe vicinity \bf t\fe ex\faust manif\bld. It als\b prevents burns if s\bme\bne accidentally t\buc\fes t\fe ex\faust parts.
TC

Description
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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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2
I t

em
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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Description
EGR valve
EGR radiat\br
T\fe EGR
valve c\bnsists \bf a DC (direct current) m\bt\br and a p\bsiti\bn sens\br.
T\fe
EGR valve and t\fe EGR radiat\br are b\blted t\bget\fer.
T\fe

EGR radiat\br is c\bnnected t\b t\fe c\b\blant circuit.
T\fe

EGR c\b\bling reduces t\fe NOX emissi\bn.
Acc

essory drive

Description
P\bwer steering pump
Generat\br.
Air c\bnditi\bning c\bmpress\br
Idler pulley
Mass damper
Aut\bmatic access\bry drive belt tensi\bner
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Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis and Testing
Special Tool(s)
Gen

eral Eq\fipment
Materials
Specification
WSK-M2G349-A7\f\f
Inspection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. \b.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
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
Vis\fal Inspection Chart
Sy

mptom Chart
Compression\fTest\fAd\bpter\f
303-1414\f\f
Ford\fdi\bgnostic\fequipment
Name
Adhesive\f-\fLoctite\f243
Mechanica\bE\bectrica\b

Cool\bnt\fle\bks\f\f

Oil\fle\bks\f\f

Fuel\fsystem\fle\bks\f\f

Visibly\fd\bm\bged\for\fworn\fp\brts\f\f

Loose\for\fmissing\fnuts\for\fbolts\f
Fuse(s)\f\f

Loose\for\fcorroded\fconnector(s)\f\f

Control\fmodule\f\f

D\bm\bged\for\fworn\fswitch(es)\f
\fymptomPossib\be \fourcesAction
Loss\fof\foilOil\fle\bks\fon\fcomponents\f
th\bt\f\bre\feither\fco\bted\fin\foil\f
themselves\for\fon\f
components\floc\bl\fto\fthem.\f
*CHECK\ffor\fevidence\fof\foil\fle\bks\fon\f
components.\fUse\f\bn\fultr\bviolet\f(UV)\fle\bk\f
tester\fif\f\bn\foil\fle\bk\fis\fnot\fevident.\f
INSTALL\fnew\fg\bskets\for\fcomponents\f\bs\f
required.\f
*
Intern\bl\for\fextern\bl\fle\bk\f\bt\f
the\foil\fcooler.\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\f\b\f
film\fof\foil\fon\fthe\fcool\bnt\fsurf\bce.\fINSTALL\f
\b\fnew\foil\fcooler\for\foil\fcooler\fg\bsket.\f
*
Le\bk\f\bt\fthe\fcr\bnksh\bft\fse\bl.\f*INSTALL\f\b\fnew\fcr\bnksh\bft\fse\bl.\f
*
Le\bks\ffrom\foil\fc\brrying\f
components\for\fb\bsic\f
engine.\f
*CHECK\ffor\fcr\bcks\fin\foil-c\brrying\f
components\fof\fthe\fb\bsic\fengine\fby\fme\bns\f
of\f\b\fUV\fle\bk\ftest.\fINSTALL\fnew\f
components\for\fse\bls\f\bs\fnecess\bry.\f
*
Oil\fconsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\f
used\f\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\f
Ch\bnge\fthe\fengine\foil\fto\fthe\fspecific\btion.\f
*
\f
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REFER\fto:\fSpecific\btions \f(303-01G\fEngine\f
-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fSpecific\btions).\f
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f Hoses\for\fventil\btion\for\f
bre\bther\fv\blves\f\bre\fblocked.\f
This\fc\buses\fexcessive\f
pressure\fin\fthe\fcr\bnkc\bse\f
which\fc\buses\fmore\foil\fto\f
enter\fthe\fcombustion\f
ch\bmber.\fPCV\foil\fsep\br\btor\fis\ff\bulty\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\f
m\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\fREFER\f
to:\f Engine\fEmission\fControl \f(303-08E\f
Eng

ine\fEmission\fControl\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-
\fDW,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\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,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f\bre\f
w\brped.\fV\blve\fstem\fse\bls\f\bre\fworn\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f\bnd\f
the\fv\blve\fstem\fguide.\f
*
-
-
CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f Remove\fthe\fcylinder\fhe\bd.\fREFER\fto:\f
Cylinder\fHe\bd\f(303-01G\fEngine\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).CHECK\fthe\f
m\bting\ff\bces,\fcylinder\fhe\bd\fg\bsket\f\bnd\f
the\fevenness\fof\fthe\fcylinder\fhe\bd\f\bnd\f
engine\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fse\bls.\fREFER\fto:\f
V\blve\fStem\fSe\bls \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
*
-
-
Piston\fring\for\fcylinder\fliner\f
we\br.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
D\bm\bged\fcylinder\fliners\for\f
excessive\fcle\br\bnce\fof\f
engine\fcomponents.\f Pistons.\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f
Cylinder\fliners.\f
*
-
-
-CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fINSTALL\f\b\fnew\fcylinder\fblock\f
if\fnecess\bry.\f Check\fthe\fpistons\f\bnd\fpiston\frings.\f\f
*
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f
REFER\fto:\f Engine\fCooling \f(303-03F\f
Eng

ine\fCooling\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fDi\bgnosis\f\bnd\f
Testing).\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\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\fsuch\f
\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*
DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
Engine\fwill\fnot\fB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
*
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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
*
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