FORD GALAXY 2006 Service Repair Manual

30.Torque:\b 23\fNm\f
31. Tighten\fthe\fcommon\fr\bil\fsupport\fbr\bcket\f ret\bining\fbolts\fin\fthe\fsequence\fshown.\fDo\fnot\f
fully\ftighten\fthe\ffuel\fsupply\fm\bnifold\fret\bining\f
br\bcket\fbolts\f\bt\fthis\fst\bge.\f
Torque:\b
1-2\f23\fNm
\f
3\f24\fNm
\f
32. CAUTION:\fUse\f\bn\fopen-ended\fwrench\f
to

\fprevent\fthe\fcomponent\ffrom\fturning.\f
NOTE:\fM\bke\fsure\fth\bt\fnew\fcomponents\f\bre\f
inst\blled.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\finjector\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\fpump\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
NOTE:\fThe\fhigh-pressure\ffuel\fsupply\flines\f
must\fbe\fconnected\fimmedi\btely\f\bfter\f
removing\fthe\fbl\bnking\fplugs.\f
NOTE:\fDo\fnot\f\bllow\fthe\funions\fto\fhit\fthe\f
ends\fof\fthe\fhigh-pressure\ffuel\fsupply\fline.\f
To\f\bid\finst\bll\btion\fof\fthe\fnew\fhigh-pressure\f
fuel\fsupply\flines,\fthe\funions\f\bt\fthe\ffuel\fr\bil\f
end\f\bre\fcolored\fgold.\f Tighten\fthe\ffuel\finjector\fhigh-pressure\ffuel\f
s u

pply\flines\fin\fthe\fsequence\fshown.\f
Torque:\b 1-5\f25\fNm
\f
6-10\f38\fNm
\f
33. Torque:\b 5\fNm\f
\f\f
\f\f
\f\f
\f
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34.Torque:\b 3\fNm\f
35. \f
36. Torque:\b 24\fNm
\f
37. Torque:\b 20\fNm
\f
38. Torque:\b 23\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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39.Torque:\b
1\f23\fNm
\f
2\f23\fNm
\f
40. Torque:\b
1\f7\fNm
\f
2\f20\fNm
\f
3\f20\fNm
\f
41. Inst\bll\fthe\fFuel\fFilter.\f Refer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\f
Lin

es\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
42. Torque:\b
1\f23\fNm
\f
2\f10\fNm
\f
43. Special\bTool(\f):\b 303-122\f
\f\f
\f\f
\f\f
\f\f
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44. Remove\fthe\fSpeci\bl\fTools.\fSpecial\bTool(\f):\b 303-435,\f303-435-06\f
45. T

orque:\b 1\f20\fNm
\f
2\f23\fNm
\f
46. M\bke\fsure\fth\bt\fthe\fG\bp\fbetween\fthe\fE\brs\fof\fthe\f V-B\bnd\fCl\bmp\fis\fbetween\f3-6\fmm.\f
Torque:\b1\f25\fNm
\f
2\f45\fNm
\f
\f
\f
\f\f
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3\f4.5\fNm\f
4\f10\fNm
\f
5\f25\fNm
\f
6\f23\fNm
\f
7\f35\fNm
\f
47. Torque:\b
1\f15\fNm
\f
2\f4\fNm
\f
48. \f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatorq-T\fCi (85kW/115PS) - \fW/\b.0L \furatorq-T\fCi (100kW/136PS) -
(103kW/140PS) - \fW, Emission Requirements: Stage IV - Specifications
Engine \fata
Lu
bricants, Fluids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Block
Pistons
Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring gaps at 1\b0 degrees to each other.
Crankshaft
Connecting Rod
Descrip\bion
Engine c\bde
Firing \brder
E\fissi\bn level
B\bre
Str\bke
Cubic capacity
C\b\fpressi\bn rati\b
P\bwer \butput at 4000 rp\f
T\brque at 1750 rp\f
Maxi\fu\f engine speed (inter\fittent)
Maxi\fu\f engine speed (c\bntin\bus)
Idle speed
Oil c\bnsu\fpti\bn
I\be\f
Engine \bil
C\b\blant
Sealant
Initial fill including \bil filter
Service fill including \bil filter
Service fill with\but \bil filter
Descrip\bion
Cylinder b\bre dia\feter
Main bearing parent b\bre dia\feter
Main bearing clearance - radial
Descrip\bion
Pist\bn dia\feter
Pist\bn clearance in cylinder
Pist\bn ring end gaps
— upper c\b\fpressi\bn ring
— l\bwer c\b\fpressi\bn ring
— \bil c\bntr\bl ring
Descrip\bion
Main bearing j\burnal dia\feter
C\bnnecting r\bd bearing j\burnal dia\feter
Crankshaft end play
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Piston Pin
Camshaft
Valves
Cylinder Head
Oil Pressure Specifications
Descrip\bion
Big end b\bre dia\feter
S\fall end b\bre dia\feter
C\bnnecting r\bd bearing clearance
Descrip\bion
Pist\bn pin length
Pist\bn pin dia\feter
Descrip\bion
Ca\fshaft end fl\bat
Ca\fshaft bearing j\burnal dia\feter
Descrip\bion
Valve ste\f dia\feter
Valve guide
Valve ste\f t\b valve guide clearance — intake valve
Valve ste\f t\b valve guide clearance — exhaust valve
Descrip\bion
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.55 - 0.60
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.61 - 0.65
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.66 - 0.70
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.71 - 0.75
Maxi\fu\f dist\brti\bn — \feasured l\bngitudinally and diag\bnally
Oil pressure at 2000 rp\f
Oil pressure at 4000 rp\f
Cylinder Bl\bck blanking plug
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Engine - \b.0L \furatorq-T\fCi (85kW/115PS) - \fW/\b.0L \furatorq-T\fCi (100kW/136PS) -
(103kW/140PS) - \fW, Emission Requirements: Stage IV - Specifications
Engine \fata
Lu
bricants, Fluids, Sealers and Adhesives
Engine Oil Capacity
Cylinder Block
Pistons
Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring gaps at 1\b0 degrees to each other.
Crankshaft
Connecting Rod
Descrip\bion
Engine c\bde
Firing \brder
E\fissi\bn level
B\bre
Str\bke
Cubic capacity
C\b\fpressi\bn rati\b
P\bwer \butput at 4000 rp\f
T\brque at 1750 rp\f
Maxi\fu\f engine speed (inter\fittent)
Maxi\fu\f engine speed (c\bntin\bus)
Idle speed
Oil c\bnsu\fpti\bn
I\be\f
F\brd F\br\fula E SAE 10W-30 M\bt\bröl
C\b\blant
Sealant
Initial fill including \bil filter
Service fill including \bil filter
Service fill with\but \bil filter
Descrip\bion
Cylinder b\bre dia\feter
Main bearing parent b\bre dia\feter
Main bearing clearance - radial
Descrip\bion
Pist\bn dia\feter
Pist\bn clearance in cylinder
Pist\bn ring end gaps
— upper c\b\fpressi\bn ring
— l\bwer c\b\fpressi\bn ring
— \bil c\bntr\bl ring
Descrip\bion
Main bearing j\burnal dia\feter
C\bnnecting r\bd bearing j\burnal dia\feter
Crankshaft end play
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Piston Pin
Camshaft
Valves
Cylinder Head
Oil Pressure Specifications
Descrip\bion
Big end b\bre dia\feter
S\fall end b\bre dia\feter
C\bnnecting r\bd bearing clearance
Descrip\bion
Pist\bn pin length
Pist\bn pin dia\feter
Descrip\bion
Ca\fshaft end fl\bat
Ca\fshaft bearing j\burnal dia\feter
Descrip\bion
Valve ste\f dia\feter
Valve guide
Valve ste\f t\b valve guide clearance — intake valve
Valve ste\f t\b valve guide clearance — exhaust valve
Descrip\bion
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.55 - 0.60
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.61 - 0.65
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.66 - 0.70
Thickness \bf cylinder head gasket with pist\bn pr\btrusi\bn \bf 0.71 - 0.75
Maxi\fu\f dist\brti\bn — \feasured l\bngitudinally and diag\bnally
Oil pressure at 2000 rp\f
Oil pressure at 4000 rp\f
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Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
Overview
Ge

neral
The\f2.0L\fDur\btorq\fTDCi\f(DW10)\fengine\fuses\fthe\fSiemens\fcommon\fr\bil\fdirect\ffuel\finjection\f
process.\f
The\fcylinder\fhe\bd\fis\fm\bde\fof\ftwo\fp\brts.\fThe\fupper\f\bnd\flower\fp\brts\f\bre\fm\bde\fof\f\bluminium\f
\bnd\f\bre\fbolted\fto\fe\bch\fother.\fThe\flower\fsection\fhouses\ffour\fv\blves\fper\fcombustion\fch\bmber\f
\bnd\fthe\fv\blve\fge\br\f\bnd\fc\bmsh\bfts.\f
The\fv\blves\f\bre\f\bctu\bted\fby\fme\bns\fof\ftwo\foverhe\bd\fc\bmsh\bfts\f\bnd\froller\ffollowers\fwith\f
\f
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