FORD GALAXY 2006 Service Repair Manual

hydr\bulic\ft\bppets.\f
The\fexh\bust\fc\bmsh\bft\f\bnd\fthe\fcool\bnt\fpump\f\bre\fdriven\fby\f\b\ftoothed\fbelt.\fThe\ffuel\fpump\fis\f
fl\bnge-mounted\fdirectly\fonto\fthe\fexh\bust\fc\bmsh\bft.\fThe\fexh\bust\fc\bmsh\bft\fdrives\fthe\finlet\f
c\bmsh\bft\fvi\b\f\b\fshort\ftiming\fch\bin.\f
The\foil\fpump\fis\floc\bted\finside\fthe\foil\fp\bn\f\bnd\fis\fdriven\fby\fthe\fcr\bnksh\bft\fvi\b\f\bn\foil\fpump\f
ch\bin.\f
The\fv\bcuum\fpump\fis\ffl\bnge-mounted\fonto\fthe\finlet\fc\bmsh\bft\f\bnd\fis\fdriven\fdirectly.\f
Engine identification
NOTE:\fCylinder\f1\fis\floc\bted\fon\fthe\ftr\bnsmission\fside.\f
Th

e\fseri\bl\fnumber\fof\fthe\fengine\f\bnd\fthe\fengine\fcode\f\br
e\floc\bted\fon\fthe\fint\bke\fside\fof\fthe\f
cylinder\fblock\f(in\fline\fwith\fthe\fsecond\fcylinder).\f
\f\f
\fescription
Engine\fcode\f
Engine\fseri\bl\fnumber\f
Cylinder head ancillary components Item
1
2
\f
Part Number -
-
Стр. 2 из 14
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\f\f\fescription
V\blve\fcover\f
positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fconnection\f
exh\bust\fg\bs\frecircul\btion\f(EGR)\fconnection\f
Cylinder\fhe\bd\f(upper\fp\brt)\f
Cylinder\fhe\bd\f(lower\fp\brt)\f
Cylinder\fhe\bd\fg\bsket\f
Valve cover Item
1
2
3
4
5
6
\f
Part Number -
-
-
-
-
-
\f
Стр. 3 из 14
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The\fv\blve\fcover\f\bnd\fthe\finlet\fm\bnifold\fform\fone\f\bssembly\f\bnd\f\bre\fm\bde\fof\fpl\bstic.\f
The\fPCV\fv\blve\fis\f\blso\floc\bted\fon\fthe\fv\blve\fcover.\f
It\fis\fse\bled\foff\ffrom\fthe\fcylinder\fhe\bd\fwith\f\b\fsep\br\bte\fse\bl.\f
The\fcylinder\fhe\bd's\fint\bke\fports\f\bnd\finjector\fports\f\bre\fe\bch\fse\bled\foff\ffrom\fthe\finlet\f
m\bnifold\fby\ffour\fse\bling\frings.\f
NOTE:\fRefer\fto\fthe\fcurrent\fservice\fliter\bture\ffor\fprec
ise\fdet\bils\fof\fhow\fto\f\bssemble\fthe\f
v\blve\fcover\f\bnd\finlet\fm\bnifold.\f
Before\fre-inst\blling\fthe\fv\blve\fcover\f\bnd\fthe\finlet\fm\bn
ifold,\fc\brefully\fcheck\fthe\fse\bling\frings\f
for\fd\bm\bge\f\bnd\frenew\fif\fnecess\bry.\f
Cylinder head
\f\f
\fescription
Se\bl\f
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Alignment\fsleeves\f
Timing\fch\bin\f
The\f\bluminium\fcylinder\fhe\bd\fh\bs\ffour\fv\blves\fper\fcombustion\fch\bmber.\fThe\fv\blve\fse\bts\f\bnd\f
gu
ides\f\bre\fm\bde\fof\fsintered\fsteel.\f
The\finlet\fports\f\bre\floc\bted\fon\fthe\ffront\fof\fthe\fcylinder\fhe\bd,\fthe\fexh\bust\fports\f\bt\fthe\fb\bck\f
(with\frespect\fto\fthe\fdirection\fof\ftr\bvel).\f Item
1
2
3
4
5
\f
Part Number -
-
-
-
-
Стр. 4 из 14
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\f\f\fescription
Inlet\fports\f
Cylinder\fhe\bd\fupper\fp\brt\f
Cylinder\fhe\bd\flower\fp\brt\f
Oil\fsupply\fhole\f
NOTE:\fThe\fupper\f\bnd\flower\fp\brts\fof\fthe\fcylinder\fhe\bd\f\bre\fm\btched\fto\fe\bch\fother\f\bnd\f
c\b
nnot\fbe\frenewed\fsep\br\btely.\f
NOTE:\fIt\fis\fimport\bnt\fto\fensure\fth\bt\fthe\foil\fsupply\fholes\f\bre\fnot\fblocked\fby\fse\bl\bnt\fwhen\f
the\ftwo\fp\brts\fof\fthe\fcylinder\fhe\bd\f\bre\fbrought\ftogether.\f
The\fcylinder\fhe\bd\fis\fm\bde\fof\ftwo\fsep\br\bte\fp\brts.\fThis\f
speci\bl\fdesign\fensures\fth\bt\fthe\f
over\bll\fstructure\fis\fstronger.\f
The\fupper\f\bnd\flower\fp\brts\fof\fthe\fcylinder\fhe\bd\f\bre\fmilled\fin\f\b\fsingle\foper\btion\f\bnd\f\bre\f
\bccur\btely\fpositioned\fwith\ftwo\f\blignment\fsleeves.\f
The\flower\fp\brt\fof\fthe\fcylinder\fhe\bd\fis\fbolted\fto\fthe\fcylinder\fblock.\f
The\fupper\fh\blves\fof\fthe\fc\bmsh\bft\fmountings\f\bre\fincorpor\bted\finto\fthe\fupper\fp\brt\fof\fthe\f
cylinder\fhe\bd.\fHere\fthe\fc\bmsh\bfts\frun\fdirectly\fin\f\bluminium,\fwithout\f\bddition\bl\fbe\bring\f
shells.\f
The\fupper\fp\brt\fof\fthe\fcylinder\fhe\bd\ffe\btures\ftop-entry\fint\bke\fports.\f
The\ftwo\findividu\bl\fp\brts\f\bre\fse\bled\fusing\f\b\fone-component,\fsilicone-b\bsed\fse\bl\bnt\fwhen\f
they\f\bre\fjoined\ftogether.\f
Valve train Item
1
2
3
4
\f
Part Number -
-
-
-
Стр. 5 из 14
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\f\f\fescription
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Roller\fc\bm\ffollower\f
Hydr\bulic\ft\bppet\f
The\finlet\fv\blves\f\bre\fm\bde\fentirely\fof\fone\fm\bteri\bl.\fThe\fhe\bds\f\bnd\fstems\fof\fthe\fexh\bust\f
v\b
lves\f\bre\fm\bnuf\bctured\ffrom\fdifferent\fm\bteri\bls\f\bnd\f\bre\fjoined\fto\fone\f\bnother\fby\fme\bns\f
of\ffriction\fwelding.\f
By\fusing\froller\ffollowers,\fit\fh\bs\fbeen\fpossible\fto\fkeep\fv\blve\f\bctu\btion\ffriction\flosses\flow.\f
V\blve\fcle\br\bnce\f\bdjustment\fis\fdone\f\butom\btic\blly\fby\fthe\fhydr\bulic\ft\bppets.\fAs\f\b\fresult,\f
there\fis\fno\fneed\fto\f\bdjust\fthe\fv\blve\fcle\br\bnces.\f
The\fhydr\bulic\ft\bppets\f\bre\fconnected\fwith\fthe\fengine's\foil\fcircuit\fby\foil\fports\fc\bst\finto\fthe\f
cylinder\fhe\bd.\f
Camshafts
\f\f
\fescription
Exh\bust\fc\bmsh\bft\f
Drive\f-\ffuel\fpump\f
Item
1
2
3
4
Item 1
2
\f
Part Number -
-
-
-
\f
Part Number-
-
-
Стр. 6 из 14
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Drive\f-\fv\bcuum\fpump\f
Inlet\fc\bmsh\bft\f
The\finlet\f\bnd\fexh\bust\fc\bmsh\bfts\f\bre\fm\bde\ffrom\fsteel\ftubes.\fThe\fc\bms\f\bnd\fends\fof\fthe\f
c\b
msh\bft\f\bre\fshrunk\fon.\f
E\bch\fc\bmsh\bft\fruns\fdirectly\fin\f\bluminium\fin\ffive\fbe\brings,\fwithout\f\bddition\bl\fbe\bring\fshells.\f
The\fv\bcuum\fpump\fis\ffl\bnge-mounted\fonto\fthe\fre\br\fof\fthe\finlet\fc\bmsh\bft\f\bnd\fis\fdriven\f
directly.\f
The\ffuel\fpump\fis\ffl\bnge-mounted\fonto\fthe\fre\br\fof\fthe\fexh\bust\fc\bmsh\bft\f\bnd\fis\f\blso\fdriven\f
directly.\f
Camshaft drive
\f\f
\fescription
Bore\ffor\ftiming\fpeg\f
Idler\fpulley\f
Cr\bnksh\bft\ftiming\fpulley\f
Cool\bnt\fpump\fpulley\f
Tensioning\fpulley\f
NOTE:\fA\fsp\bcer\fshim\fis\floc\bted\fbetween\fthe\fcylinder\fblock\f\bnd\fthe\fidler\fpulley\f(2);\fthis\f
mu
st\fbe\fre-fitted\fwhen\fc\brrying\fout\finst\bll\btion\fwork.\f
The\fexh\bust\fc\bmsh\bft\fis\fdriven\fby\f\b\ftoothed\fbelt.\fThe\f
toothed\fbelt\f\blso\fdrives\fthe\fcool\bnt\f
pump.\f
The\ftoothed\fbelt\fdrive\fh\bs\f\bn\f\butom\btic\ftensioning\fpulley.\fThe\ftensioning\fpulley\foper\btes\f
by\fspring\fforce.\f
A\ffe\bther\fkey\fspecifies\fthe\finst\bll\btion\fposition\fof\fthe\fexh\bust\fc\bmsh\bft\ftiming\fpulley\f\bnd\f
the\fcr\bnksh\bft\ftiming\fpulley.\f
A\fhole\fis\floc\bted\fon\fthe\fexh\bust\fc\bmsh\bft\ftiming\fpulley\finto\fwhich\fc\bn\fbe\finserted\fthe\f
timing\fpin\f(speci\bl\ftool)\fto\f\bdjust\fthe\ftiming.\f
Timing chain tensioner 3
4
I t

em
1
2
3
4
5 -
\f
Part Number
-
-
-
-
-
Стр. 7 из 14
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\f\f\fescription
Timing\fbelt\fpulley\f-\fexh\bust\fc\bmsh\bft\f
Timing\fch\bin\ftensioner\f
Exh\bust\fc\bmsh\bft\fsprocket\f
Inlet\fc\bmsh\bft\fsprocket\f
The\ftiming\fch\bin\ftensioner\fis\f\btt\bched\fto\fthe\fupper\fp\brt\fof\fthe\fcylinder\fhe\bd,\fbetween\fthe\f
c\b
msh\bft\fsprockets.\f
Two\fsecuring\fbolts\f\bre\fused\fto\fsecure\fthe\fch\bin\ftensioner.\f
\f\f
\fescription
Timing\fch\bin\ftensioner\fhousing\f
Spring\f
Timing\fch\bin\fguide\f
Oil\fbore\f
The\ftiming\fch\bin\fguide\fis\fm\bde\fof\fpl\bstic.\f
Ti

ming\fch\bin\fguide\fwe\br\fis\fcompens\bted\ffor\fby\f\b\fspring\flo\bded\ftiming\fch\bin\ftensioner.\f
Bec\buse\fthe\ftiming\fch\bin\ftensioner\fis\fconnected\fto\fthe\fengine\foil\fsupply\fcircuit,\fthe\f
components\f\bre\flubric\bted\f\bnd\fch\bin\fnoise\fis\freli\bbly\fprevented.\f
A\fsecond\ftiming\fch\bin\fguide\fis\f\btt\bched\fto\fthe\fcylinder\fhe\bd\flower\fsection.\f
Timing chain
\f\f
Item 1
2
3
4
Item 1
2
3
4 \f\fPart Number
-
-
-
-
\f\f
Part Number-
-
-
-
\f\f
Part Number
Стр. 8 из 14
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\fescription
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Bright\fchrome-finished\fch\bin\flinks\f
M\brkings\fon\fthe\fsprockets\f
The\finlet\fc\bmsh\bft\fis\fdriven\fvi\b\f\b\ftiming\fch\bin.\f
Th

e\ftiming\fch\bin\fis\ftensioned\fusing\f\bn\f\butom\btic\fch\bin\ftensioner.\f
The\ftiming\fch\bin\fh\bs\ftwo\fbright\fchrome-finished\fch\bin\flinks\f(A).\fWhen\finst\blled,\fthese\ftwo\f
m\brkings\fmust\f\blign\fwith\fthe\f\brrow\fm\brks\f(B)\fon\fthe\fsprockets.\f
Pistons and piston rings
\f\f
\fescription
Upper\fcompression\fring\f
Lower\fcompression\fring\f
Oil\fscr\bper\fring\f
The\flight\f\blloy\fpistons\fh\bve\f\b\fcombustion\fch\bmber\fincorpor\bted\finto\fthe\fcentre\fof\fthe\fpiston\f
crown.\fThis\foptimises\fswirling\fof\fthe\ffuel/\bir\fmixture.\f
Two\frecesses\f\bre\fincorpor\bted\finto\fe\bch\fpiston\fcrown.\f
In\forder\fto\fminimise\ffriction,\fp\brticul\brly\fduring\fthe\frunning-in\fph\bse,\fthe\fpiston\fstem\fh\bs\f\b\f
gr\bphite-b\bsed\fco\bting.\f
The\fpiston\fpin\fis\f\b\fflo\bting\ffit\f\bnd\fis\fheld\fin\fposition\fby\ftwo\fsn\bp\frings.\f
Cylinder block Item
1
2
( A

)
(B)
Item 1
2
3 -
-
-
-
\f
Part Number
-
-
-
Стр. 9 из 14
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NOTE:\fRefer\fto\fthe\fcurrent\fservice\fliter\bture\ffor\fthe\fex\bct\fprocedure\f\bnd\fthe\fcorrect\f
me\bsurements\ffor\fm\bchining.\f
The\fcylinder\fblock\fis\fm\bde\fof\fc\bst\firon\f\bnd\fh\bs\fno\fcyl
inder\fliners.\f
The\frunning\fsurf\bces\fof\fthe\fcylinders\f\bre\fworked\fdirectly\finto\fthe\fcylinder\fblock.\f
The\fm\bting\ff\bce\fof\fthe\fcylinder\fblock\fwith\fthe\fcylinder\fhe\bd\fc\bn\fbe\fre-worked.\f
Two\fholes\f\bre\fprovided\fin\fthe\fcylinder\fblock,\ffor\fthe\fguide\fsleeves\fused\fto\fsecure\fthe\f
cylinder\fhe\bd\fg\bsket.\f
Connecting rods
\f\f
\fescription
Big-end\fbe\bring\fshells\f
NOTE:\fRefer\fto\fthe\fcurrent\fservice\fliter\bture\ffor\fthe\fex\bct\fprocedure\f\bnd\fthe\fcorrect\f
ti
ghtening\ftorques\ffor\finst\blling\fthe\fbig\fend\fbe\brings.\f
The\fconnecting\frods\f\bre\fm\bde\fof\fforged\fsteel.\f
The

\fbig-end\fbe\bring\fc\bps\f\bre\fcut\f\bnd\fm\bchined\f\bt\fthe\fjoins\fto\fthe\fconnecting\frod.\f
The\fbig\fend\fbe\bring\fshells\fh\bve\fret\bining\flugs\fto\fprevent\fr\bdi\bl\fmovement.\f
The\fret\bining\fnuts\f\bre\ftightened\fin\fthree\fst\bges.\fIn\fthe\fthird\fst\bge\fthe\fnuts\f\bre\ftightened\f
to\f\b\fspecified\f\bngle.\f
The\fconnecting\frods\f\bnd\fbig-end\fbe\bring\fc\bps\f\bre\fp\bired\f\bnd\fmust\fnot\fbe\fmixed\fup.\f
Crankshaft main bearings Item
1
\f
\f\f
Part Number -
Стр. 10 из 14
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\f\f\fescription
Colour\fm\brking\f
M\brking\f
B\brcode\f
Alph\bnumeric\bl\fcode\f
Thrust\fw\bshers\f
M\brking\f
For\f\bccur\bte\f\bdjustment\fof\fthe\fcr\bnksh\bft\fbe\bring\fcle\br\bnce,\fthe\fcr\bnksh\bft\fbe\bring\fshells\f
in
\fthe\fcr\bnksh\bft\fm\bin\fbe\bring\fc\bps\f\bre\f\bv\bil\bble\fin\ffive\fdifferent\fthicknesses.\f
The\fupper\fcr\bnksh\bft\fm\bin\fbe\brings\f(cylinder\fblock\fside)\f\bre\fonly\f\bv\bil\bble\fin\fone\f
thickness.\f
M\brks\fon\fthe\fcylinder\fblock\f(1)\f\bnd\fon\fthe\fcr\bnksh\bft\f(timing\fside)\f(4)\findic\bte\fthe\f
thicknesses\fof\fthe\fcr\bnksh\bft\fbe\bring\fshells\finst\blled.\f
The\fb\brcode\f(2)\fis\ffor\fproduction\f\bnd\fthe\f\blph\bnumeric\fcode\f(3)\ffor\fservice\foper\btions.\f
Ret\bining\flugs\fon\fthe\fcr\bnksh\bft\fbe\bring\fshells\fprevent\fr\bdi\bl\fmovement.\f
NOTE:\fThe\fcr\bnksh\bft\fm\bin\fbe\bring\fc\bps\fmust\fbe\finst\bl l
ed\fin\fthe\fcorrect\fposition.\f
NOTE:\fCylinder\f1\fis\floc\bted\fon\fthe\ftr\bnsmission\fside.\f Item
A1
2
3
4
5
\f
Part Number -
-
-
-
-
-
Стр. 11 из 14
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