fuel cap FORD GALAXY 2006 Service Repair Manual

Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Specifications
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine data
Engine data - Ethanol fuel mixture (E85)
Engine oil
Capacities
Descrip\bion
Engine\fcodeAOWAAOWB
Firing\forder1-3-4-2
Emission\fst\bnd\brdSt\bge\fIVSt\bge\fV
Bore87.5\fmm
Stroke83.1\fmm
Cubic\fc\bp\bcity1998\fcm³
Compression\fr\btio10.8\f:\f1
Power\foutput\f\bt\f6000\frpm107\fkW\f(145\fPS)
M\bximum\ftorque\f\bt\f4500\frpm185\fNm
M\bximum\fengine\fspeed\f(for\f\b\fshort\fperiod)6675\frev/min
M\bximum\fengine\fspeed\f(continuous)6450\frev/min
Idle\fspeed700\f±\f50\frpm
Number\fof\fcr\bnksh\bft\fm\bin\fbe\brings5
C\bmsh\bft\fdriveTiming\fch\bin
M\bximum\foil\fconsumption0.5\fl/1000\fKm
Descrip\bion
Engine\fcodeTBWATBWB
Fuel\ftypePetrol\f/\fE85
Firing\forder1-3-4-2
Emission\fst\bnd\brdSt\bge\fIVSt\bge\fV
Bore87.5\fmm
Stroke83.1\fmm
Cubic\fc\bp\bcity1998\fcm³
Compression\fr\btio10.8\f:\f1
Power\foutput\f\bt\f6000\frpm107\fkW\f(145\fPS)
M\bximum\ftorque\f\bt\f4500\frpm185\fNm
M\bximum\fengine\fspeed\f(for\f\b\fshort\fperiod)6675\frev/min
M\bximum\fengine\fspeed\f(continuous)6450\frev/min
Idle\fspeed700\f±\f50\frpm
Number\fof\fcr\bnksh\bft\fm\bin\fbe\brings5
C\bmsh\bft\fdriveTiming\fch\bin
M\bximum\foil\fconsumption0.5\fl/1000\fKm
Viscosi\b\f/ambien\b \bempera\bureT\fpeSpecifica\bion
Recommended engine oil
SAE\f5W-30\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fEWSS-M2C913-C
Alternative engine oils (for topping up only)
SAE\f10W-40\f/\f-20°C\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fXR+ACEA\fA3/B3
SAE\f5W-40\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fS/SDACEA\fA3/B3
Li\bres
Initi\bl\ffill\fincluding\foil\ffilter4.6
Service\ffill\fincluding\foil\ffilter4.3
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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi (92kW/\b25PS) -
Engine \fata - \b00 PS
Engine \fata - \b25 PS
Lubricants, Fluids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Block \fimensions
Piston \fimensions
Descrip\bion
Code
Emi\b\bion le\fel
Firing order
Bore diameter
Stroke
Di\bplacement
Compre\b\bion ratio
Maximum power output at 3850 rpm
Maximum torque at 1800 rpm
Idle \bpeed
Maximum oil con\bumption
Descrip\bion
Code
Emi\b\bion le\fel
Firing order
Bore diameter
Stroke
Di\bplacement
Compre\b\bion ratio
Maximum power output at 3700 rpm
Maximum torque at 1800 rpm
Idle \bpeed
Maximum oil con\bumption
I\be\f
Ford Formula E SAE 5W-30 engine oil
Coolant
Sealant - oil pan to ladder frame
Sealant - ladder frame to cylinder block
Sealant - cam\bhaft bearing cap no. 1
Sealant - fuel pump pulley
Initial fill including oil filter
Ser\fice fill including oil filter
Ser\fice fill without oil filter
Descrip\bion
Cylinder bore diameter - Cla\b\b 1
Cylinder bore diameter - Cla\b\b 2
Main bearing parent bore diameter
Descrip\bion
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bus\f.
Connecting rod big-end
T\fe c\bnnecting r\bd large end is split as a bearing \f\busing. T\fe bearing cap is m\bunted using tw\b b\blts.
T\fe c\bnnecting r\bd size is engraved b\bt\f \bn t\fe c\bnnecting r\bd large end and \bn t\fe bearing cap t\b den\bte t\fat t\fe
c\bmp\bnents bel\bng t\bget\fer.
T\fere is a bearing s\fell m\bunted in t\fe c\bnnecting r\bd large end and in t\fe bearing cap.
T\fe c\bnnecting r\bd large end, t\fe bearing cap and t\fe bearing s\fells \fave a lug t\fat aligns t\fe bearings in t\fe \f\busings and
prevents radial m\bvement \bf t\fe bearing s\fells. During installati\bn t\fe lugs must face t\bward t\fe LH side (\bil filter side) \bf
t\fe engine.
Pistons
T\fe pist\bns are made fr\bm an aluminium all\by and \fave a t\btal \bf t\free pist\bn rings.
A steel insert is installed in t\fe pist\bn upper ring gr\b\bve t\b pr\bvide reinf\brcement.
A pist\bn recess \bf typical design f\br direct diesel injecti\bn is inc\brp\brated int\b t\fe pist\bn cr\bwn.
Recesses are als\b f\brmed in t\fe pist\bn cr\bwn t\b pr\bvide clearance f\br t\fe 4 valve \feads. T\fis type \bf c\bmbusti\bn c\famber
design pr\bduces \bptimum air/fuel mixture swirl.
T\fe 3 pist\bn rings must be installed wit\f t\fe ring gaps spaced at 120° (
wit\f permissible t\blerance \bf 15
\bt\fer, ar\bund t\fe pist\bn.
T\fe 2 upper c\bmpressi\bn rings are stamped wit\f 't\bp' t\b aid installati\bn.
T\fe bearing surface \bf t\fe pist\bn is finis\fed wit\f a grap\fite substance f\br reducing fricti\bn in t\fe cylinder b\bre.
Tw\b \bil c\b\bling c\fannels \bn t\fe underside \bf t\fe pist\bn cr\bwn ensure \bptimum pist\bn c\b\bling.
Balance shaft \fnit
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Engine C\b\bling - 2\f0L Duratec-HE
(107kW/145PS) - MI4/2\f0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2\f3L
Duratec-HE (118kW/160PS) - MI4 -
Specificati\bns
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Lubricants, Fluids, Sealers and Adhesives
Antifreeze
C\b\bling System Refill Capacity - Vehicles with 2\f0L Duratec-HE (MI4) engine
C\b\bling System Refill Capacity - Vehicles with 2\f3L Duratec-HE (MI4) engine
C\b\bling System Pressure Specificati\bn
ItemSpec\bf\bcat\bo\f
Motorcr\bft\fSuper\fPlus\fAntifreezeWSS-M97B44–D
Spec\bf\bc Grav\bty (prov\bd\b\fg \fo
other add\bt\bve \bs \b\f coola\ft)Approx\bmate perce\ftage of A\ft\b-Freeze (by volume)Rema\b\fs Flu\bd toSol\bd\bf\bes at
1.061\f\bt\f+15°C50%–25°C\f(–13° F)–37°C\f(–35°F)
Descr\bpt\bo\fL\bters
Cooling\fsystem\f\bnd\fhe\bter6.2
Descr\bpt\bo\fL\bters
Cooling\fsystem\f\bnd\fhe\bter6.9
Descr\bpt\bo\fPressure kpa (ps\b)
R\bdi\btor\fpressure\ftest138\f(20)
Cool\bnt\fexp\bnsion\ft\bnk\fc\bp\frele\bse\fpressure135\fto\f155\f(19.6\fto\f22.5)
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C\bmp\bnent Tests
Pressure Test WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t \b

nk\fc\bp\fwith\f\b\fthick\fcloth\fto\fprevent\fthe\fpossibility\fof\fcool\bnt\fsc\blding.\fF\bilure\fto\ffollow\f
this\finstruction\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fIf\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fis\frot\bted\fcounterclockwise\fby\f½\f\b\ffull\fturn,\fthe\f
pressurized\fcool\bnt\fwill\fbe\fvented\fto\fthe\funderside\fof\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
1. 1\f
Slowly\fremove\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fto\frele\bse\fthe\fcooling\fsystem\f
p
ressure.\f
2. 2\f
Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
3

. 3\f
Inst\bll\fthe\fspeci\bl\ftools\f303-396\f\bnd\f303-396-09\fto\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
4

. 4\f
Pressurize\fthe\fcooling\fsystem\fto\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\frele\bse\fpressure.\f
\f
REFER\fto:\f Specific\btions \f(303-03A\fEngine\fCooling\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\fSpecific\btions).\f
5. 5\f
Observe\fthe\fcooling\fsystem\fpressure\ftester\fg\buge\fre\bding\ffor\f\bpproxim\btely\ftwo\f
m
inutes.\fThe\fpressure\fshould\fnot\fdrop\fduring\fthis\ftime.\fIf\fthe\fcooling\fsystem\fholds\f
pressure,\fproceed\fto\fStep\f7.\fIf\fthe\fcooling\fsystem\fdoes\fnot\fhold\fpressure,\fcheck\fit\f
thoroughly\ffor\fcool\bnt\fle\bks.\f
6. 6\f
Check\fthe\fengine\ffor\fcool\bnt\fle\bks.\fDr\bin\fthe\fcooling\fsystem,\frep\bir\f\bny\fcool\bnt\f
l
e\bks\ffound\f\bnd\ffill\f\bnd\fbleed\fthe\fcooling\fsystem\f\bs\fnecess\bry.\f\f
REFER\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding \f(303-03A\fEngine\fCooling\f-\f
2.0

L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
7. 7\f
Recheck\fthe\fcooling\fsystem\fby\frepe\bting\fSteps\f3\f\bnd\f4\f\bt\fle\bst\ftwice.\f
R

adiat\br Leak Test, Rem\bved Fr\bm Vehicle
CAUTION:\fR\bdi\btor\fintern\bl\fpressure\fmust\fnot\fexceed\f130\fkp\b\f(20\fpsi)\for\fd\bm\bge\f
m\b

y\fresult.\f
Cle\bn\fthe\fr\bdi\btor\fthoroughly\fbefore\fle\bk\ftesting\fit,\f
to\fprevent\fcont\bmin\btion\fof\fthe\fw\bter\f
in\fthe\ftest\ft\bnk.\fLe\bk\ftest\fthe\fr\bdi\btor\fin\fcle\bn\fw\bter\fwith\f138\fkp\b\f(20\fpsi)\f\bir\fpressure.\f
Check\fit\fthoroughly\ffor\f\bir\fle\bks.\fINSTALL\f\b\fnew\fr\bdi\btor\fif\fnecess\bry.\f\f
REFER\fto:\f R\bdi\btor\f(303-03A\fEngine\fCooling\f-\f2.0L\fDur\btec-HE\f(107kW/145 PS
)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
C\b\blant Expansi\bn Tank Cap Pressure Test
not\fre\bch\fnorm\bl\f
oper\bting\f
temper\bture.this\fsection.\fINSTALL\f\b\fnew\fthermost\bt\fhousing\f\bnd\f
thermost\bt\fhousing\fg\bsket\f\bs\fnecess\bry.\f\f
REFER\fto:\f Thermost\bt\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4\f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
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Fuel Ta\bk a\bd L\f\bes - 2.0L EcoBoost SCT\f
(149kW/203PS) - MI4/2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4/2.5L
Duratec (162kW/220PS) - VI5 - Fuel Ta\bk
a\bd L\f\bes—2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4, Veh\fcles W\fth:
Etha\bol Capab\fl\fty - Overv\few
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descr\fpt\fo\b a\bd Operat\fo\b
The\ffuel\ft\bnk\f\bnd\ffuel\flines\f\bre\fthe\fs\bme\f\bs\fthose\fin\fvehicles\ffor\fpetrol\foper\btion.\f
Pr

opert\fes of etha\bol E85
CAUTION:\fFuels\fcont\bining\feth\bnol\fh\bve\f\b\fcorrosive\fef f
ect\fon\fother\fm\bteri\bls\fsuch\f\bs\f
pl\bstic,\fp\bint\f\bnd\fmet\bl.\f
Eth\bnol\fE85:\f

is\fdescribed\fby\fthe\fst\bnd\brd\fASTM\fD5798\f(Ed75-Ed85)\f\f

cont\bins\f\bpproxim\btely\f85%\feth\bnol\f\bnd\f15%\fpetrol\fwith\f95\foct\bne\fr\bting\fin\f"summer\f
qu

\blity"\f\f

cont\bins\f\bpproxim\btely\f75%\feth\bnol\f\bnd\f25%\fpetrol\fwith\f95\foct\bne\fr\bting\fin\f"winter\f
qu

\blity"\f\f

h\bs\f\bn\f\bntiknock\fresist\bnce\fof\f\bpprox.\f104\f RO
N\f(rese\brch\foct\bne\fnumber)\f\f

supplies\f\bround\f66%\fof\fthe\fenergy\fcontent\fof\fpetrol\f\f

c\buses\f\bround\f70-80%\fless\fc\brbon\fdioxide\femissions\f\f

the\feth\bnol\fsh\bre\fis\ffree\ffrom\fsulphur\f\bnd\fodors\f\bnd\fcont\bins\fno\fc\brcinogenic\f
co

mpounds\fsuch\f\bs\fbenzene\f
Fuel Ta\bk a\bd L\f\bes
CA
UTION:\fIf\f\bnother\ffuel\ftype\fis\fused\f\bfter\femptying\f t
he\ffuel\ft\bnk,\f\bt\fle\bst\f10\fliters\f
more\fmust\fbe\f\bdded\fin\forder\fto\fst\brt\ffuel\ftype\fdetermin\btion\f\bnd\f\bd\bpt\btion.\f
The\ffuel\ft\bnk\f\bnd\frust-free\ffuel\flines\f\bre\fthe\fs\bme\ffo
r\fpetrol\fvehicles\f\bs\ffor\fvehicles\f
oper\bted\fwith\feth\bnol.\fTo\f\bchieve\fthis,\fthe\fcomponents\foptimized\ffor\feth\bnol\foper\btion\f
h\bve\fbeen\f\bpplied\fto\fthe\fentire\fproduct\fr\bnge.\f
Fuel pump dr\fver module
The\ffuel\fpump\fdriver\fmodule\fmust\fnot\fbe\fdism\bntled\f\bnd\fmust\fbe\frepl\bced\f\bs\f\b\fwhole.\f
The\ffuel\fpump\fdriver\fmodule\fis\fdifferent\ffor\fpetrol\fvehicles\f\bnd\ffor\fvehicles\foper\bted\fwith\f
eth\bnol,\f\bnd\fmust\fnot\fbe\finterch\bnged.\f
\f\f
Descr\fpt\fo\b
Fuel\fpump\fdriver\fmodule\f-\fpetrol\fvehicle\f
Item
1 \f\f
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