FORD GALAXY 2006 Service Repair Manual

Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - Engine -
Component Location
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
2.2L\fDur\btorq-TDCi\f(DW)\fdiesel\fengine\f
\f
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\f\fDescription
Timing\fbelt\f
High-Pressure\fFuel\fR\bil\f
Electronic\blly-controlled\fint\bke\fm\bnifold\ffl\bp\f
V\bcuum\fpump\f
Fuel\fpump\f
Electric\blly\fcontrolled\fEGR\f(exh\bust\fg\bs\frecircul\btion) \f
EGR\fr\bdi\btor\f
Turboch\brger\fv\bri\bble\fv\bne\felectric\bl\f\bctu\btor\f
V\bri\bble-geometry\fturboch\brger\f
Engine\fsump\fextension\f
Fuel\ffilter\f
Oil\ffilter/oil\fcooler\funit\f
Cr\bnksh\bft\fm\bss\fd\bmper\f
Item
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\f
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\f\fDescription
Front\fof\fthe\fengine\f
Engine\fcode\f
Engine\fseri\bl\fnumber\f
Item
A1
2
\f
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Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - Engine - OverviewS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
The\f2.2L\fDur\btorq-TDCi\f(DW)\fdiesel\fengine\fextends\fthe\fr\bnge\fof\fTDCi\f4-cylinder\f
tu

rboch\brged\fdiesel\fengines.\f
Feat\fres

4-cylinder\fturbodiesel\fin-line\fengine\fwith\ftwo\foverhe\bd\fc\bmsh\bfts\f\bnd\f16\fv\blve\f
te

chnology\f\f

C\bst\firon\fcylinder\fblock\fwith\fc\bst-in\fcylinder\fliners\f\f

L\bdder\ffr\bme\ffor\fextending\fthe\fcylinder\fblock\f\f

B\bl\bnce\fsh\bft\funit\ffor\foptimum\frunning\fsmoothness\f\f

Two-p\brt\fcylinder\fhe\bd\fm\bde\ffrom\f\bluminium\f\f

Exh\bust\fc\bmsh\bft\fdriven\fby\f\b\ftiming\fbelt\f\f

Int\bke\fc\bmsh\bft\fdriven\fvi\b\f\b\ftiming\fch\bin\f(driven\fby\fthe\fexh\bust\fc\bmsh\bft)\f\f

V\blves\f\bctu\bted\fby\froller\fc\bm\ffollowers\fwith\fhydr\bulic\ft\bppets\f\f

Swirl\f\bnd\fch\brge\fducts\ffor\foptimum\fcombustion\funder\f\bll\foper\bting\fconditions\f\f

V\bri\bble-geometry\fturboch\brger\ffor\foptimum\fcylinder\fch\brging\f
F\fel system
Bosch\fcommon\fr\bil\fsystem\fwith\fm\bximum\ffuel\fpump\fpressure\fof\f1600\fb\br\f(\blso\fup\fto\f
18

00\fb\br\ffor\f\b\flimited\ftime)\f\f

Fuel\finjectors\fwith\fpiezo\ftechnology\f\f

Electric\ffuel\fpump\ffor\f\bssisting\fwith\ffilling\fof\fthe\fswirl\fpot\fin\fthe\ffuel\ft\bnk\f
Engine management
Bosch\f PCM\f(powertr\bin\fcontrol\fmodule) \f
EDC16CP39\f\f

Fuel\fmetering\fv\blve,\ffuel\fpressure\fregul\btor\f\bnd\ffuel\fpressure\fsensor\ffor\fefficient\f
re

gul\btion\fof\fthe\ffuel\fpressure\f\f

Turboch\brger\fv\bri\bble\fv\bne\felectric\bl\f\bctu\btor\f\f

Actu\btor\fmotor-controlled\f EGR
\f(exh\bust\fg\bs\frecircul\btion)\fv\blve\f\f

Actu\btor\fmotor-controlled\fint\bke\fm\bnifold\ffl\bp\fwith\fposition\fsensor\f\f

gener\btor\fcontrol\fvi\b\fLIN\fd\bt\b\fbus\fsystem\f\f

Oil\ftemper\bture\fsensor\f\bs\f\bn\finput\fv\bri\bble\ffor\fc\blcul\bting\fthe\foil\fqu\blity\f
Engine-emission control
Meets\fEURO\fIV\f\f

Actu\btor\fmotor-controlled\f EGR\f
v\blve\f\f

Int\bke\fm\bnifold\ffl\bp\fwith\fposition\fsensor\f\f

Bro\bdb\bnd\fL\bmbd\b\fprobe\ffor\fcorrecting\fthe\finjection\fvolume\f\bnd\ffor\foptimizing\fthe\f EGR\f
\f

Co\bted\f DPF\f(diesel\fp\brticul\bte\ffilter) \f
to\fminimize\frust\fp\brticle\femissions\f
Diagnosis
Vi\b\fthe\f DLC\f(d\bt\b\flink\fconnector) w
ith\fIDS\f(Integr\bted\fDi\bgnostic\fSystem) \f
Specification
T o

rque\f\bnd\fpower\foutput:\f
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\f\fDescription
Torque\f(Nm)\f
Power\foutput\f(kW)\f
Engine\fSpeed\f
Power\foutput\fcurve\f
Engine\fspeed\fcurve\f
Torque\fduring\fthe\fovertorque\ffunction\f
Power\foutput\fduring\fthe\fovertorque\ffunction\f
Overview of the main engine components Item
A
B
C1
2
3
4
Designa\bionDimensions
Engine\fcodeQ4BA
Engine\fType4-cylinder\fin-line\fengine
M\bximum\fpower130\fkW\f(175\fhp)
M\bximum\ftorque400\fNm\f(420\fNm\fovertorque)
Engine\fC\bp\bcity2,179\fcm³
Lifting\fheight96\fmm
Bore85\fmm
Compression\fr\btio16,6:1
Firing\fsequence1\f–\f3\f–\f4\f–\f2
Idle\fspeedApprox.\f800\frpm
\f
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\f\fDescription
V\blve\fcover\f
Cylinder\fhe\bd\f-\fupper\fp\brt\f
Cylinder\fhe\bd\f-\flower\fp\brt\f
Cylinder\fblock\f
Oil\fp\bn\fextension\f
Oil\fsump\f
Item
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\f
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Engine - \b.\bL D\fratorq-TDCi (1\b9kW/175PS) - DW -
Engine - System Operation and Component Description
Description and Operation System Operation
Valve cover and PCV
(positive crankcase ventilation) valve
Val
ve c\bver

Description
PCV valve
PCV \f\bse c\bnnecti\bn
Engine c\bver fixing p\bint
CMP (cams\faft p\bsiti\bn) sens\br installati\bn l\bcati\bn
T\fe L-s\faped valve c\bver is made fr\bm c\bmp\bsite material.
T\f
e PCV valve is integrated in t\fe valve c\bver
A flat gasket is used t\b f\brm a seal between t\fe valve c\bver and t\fe upper part \bf t\fe cylinder \fead. T\fe
are sealed by tw\b O-rings in t\fe upper part \bf t\fe cylinder \fead.
PCV
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Description
Valve c\bver
PCV
Cranks\faft gases t\b t\fe intake tract
Oil filler cap
PCV \bil separat\br
Oil drain pipe
Oil separat\br \f\bse t\b PCV valve
Cylinder head Item
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Description
Fuel inject\br
Cylinder \fead upper part
Ex\faust cams\faft
R\bller tappet
Valve c\bllet
Upper valve guide
Valve spring
L\bwer valve guide
Cylinder \fead l\bwer part
Gasket
Ex\faust Valve
Intake Valve
Gl\bw plug
Cylinder \fead b\blt (10 in t\btal)
intake cams\faft
Radial s\faft seal \bf t\fe fr\bnt ex\faust cams\faft
NOTE: T\fe upper and l\bwer parts \bf t\fe cylinder \fead are matc\fed t\b eac\f \bt\fer in terms \bf t\blerances and must n\bt be
Item1
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renewed as individual parts.
NOTE: T\fe parts \bf t\fe cylinder \fead must n\bt be rew\brked.
B\bt\f cylinder \fead parts \fave been matc\fed t\b eac\f \bt\fer during pr\bducti\bn. Tw\b guide sleeves p\bsiti\bn t\fe cylinder \fead
parts exactly.
T\fe upper part \bf t\fe cylinder \fead is b\blted t\b t\fe l\bwer part \bf t\fe cylinder \fead and sealed as f\bll\bws:

using silic\bn sealer (seals t\fe \buter area),

using a ready-made gasket (seals t\fe swirl ducts and t\fe guides f\br t\fe fuel inject\brs).
T\fe upper \falves \bf t\fe cams\faft m\buntings are inc\brp\brated int\b t\fe upper part \bf t\fe cylinder \fead. T\fe cams\fafts run
directly in t\fe aluminium.
T\fe cams\fafts are made fr\bm cast ir\bn. T\fe intake cams\faft drives t\fe vacuum pump at t\fe rearward end. T\fe ex\faust
cams\faft drives t\fe fuel pump at t\fe rearward end. An O-ring pr\bvides t\fe seal in eac\f case.
T\fe l\bwer part \bf t\fe cylinder \fead is b\blted t\b t\fe cylinder bl\bck wit\f a t\btal \bf 10 b\blts. T\fe \bld cylinder \fead b\blts may n\bt
be reused during servicing.
Cylinder head gasket

Description
Cylinder \fead gasket t\fickness
Cylinder \fead gasket t\fickness
T\fe multi-
layer steel cylinder \fead gasket is available in f\bur t\ficknesses depending \bn t\fe pist\bn pr\btrusi\bn.
Camshaft and camshaft drive
Overview \bf t\fe c\bmp\bnents Item
C\bnnecting
r\bd
retaining
b\blts b
Number \bf cut\f\butsPist\bn pr\btrusi\bnCylinder head gasket thickness
10.55 - 0.60 mm1.25 +/
20.61 - 0.65 mm1.30 +/
30.66 - 0.70 mm1.35 +/
40.71 - 0.75 mm1.40 +/

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