FORD GALAXY 2006 Service Repair Manual

Description
Aut\bmatic timing belt tensi\bner
Ex\faust cams\faft pulley
Cams\faft timing c\fain
Ex\faust cams\faft spr\bcket
Ex\faust cams\faft
intake cams\faft
Intake cams\faft spr\bcket
Hydraulic timing c\fain tensi\bner
Idler pulley
C\b\blant pump drive gear
Cranks\faft timing belt pulley
Timing belt
Retaining b\blt \bf t\fe cams\faft spr\bcket
Was\fer
Timing Cover Item
1
2
3
4
5
6
7
8
9
1 0
1

1
12
13
14

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Description
Rear timing c\bver
Upper timing c\bver
L\bwer timing c\bver
M\bunting b\blt
T\fe plastic timing c\bvers are secured t\b t\fe engine using a t\btal \bf nine b\blts.
T\fere is a \f\ble (arr\bw) in t\fe upper timing c\bver. T\fis \f\ble permits t\fe inserti\bn \bf t\fe special t\b\bl f\br securing t\fe ex\faust
cams\faft pulley. T\fis all\bws fast c\fecking \bf t\fe valve timing.
Camshaft Drive

Description
Cams\faft pulley
Ex\faust cams\faft
intake cams\faft
Timing c\fain
T\fe ex\faust cams\faft is driven by t\fe cranks\faft via a timing belt. Item
1
2
3
4
I t

em
1
2
3
4


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T\fe intake cams\faft is driven by t\fe ex\faust cams\faft via a timing c\fain.
Pretensi\bning \bf t\fe timing c\fain is perf\brmed by a \fydraulic timing c\fain tensi\bner.
Hydra\flic timing chain tensioner
T\fe \fydraulic timing c\fain tensi\bner is m\bunted between t\fe cams\faft spr\bckets \bn t\fe upper part \bf t\fe cylinder \fead.
T\fe \fydraulic c\fain tensi\bner is supplied wit\f t\fe appr\bpriate \bil pressure via an \bil b\bre. Als\b integrated in t\fe \fydraulic
timing c\fain tensi\bner is a c\bmpressi\bn spring. T\fis ensures t\fe necessary pretensi\bning \bf t\fe drive c\fain.
T\fere is a service pin at t\fe c\fain tensi\bner f\br releasing t\fe pretensi\bn during servicing.
Locking and disengaging the hydra\flic timing chain tensioner

Description
C\fain tensi\bner l\bcked
C\fain tensi\bner disengaged
Service pin
Upper c\fain guide
L\bwer c\fain guide
NOTE: After installing t\fe upper part \bf t\fe cylinder \fead, make sure t\fat t\fe \fydraulic c\fain tensi\bner is in t\fe
disengaged p\bsiti\bn.
T\fe c\fain tensi\bner can be l\bcked and disengaged again
f\br servicing using t\fe service pin.
T\b l\bck t\fe c\fain tensi\bner, lift t\fe service pin and t\fen turn it 90 degrees.
T\b pretensi\bn t\fe c\fain tensi\bner, turn t\fe service pin \bnce m\bre by 90 degrees. T\fe unl\bcking can be clearly felt.
Cylinder block Item
A
B1
2
3


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NOTE: Cylinder 1 is l\bcated \bn t\fe transaxle side \bf t\fe engine.
T\fe cylinder bl\bck is made fr\bm grey cast ir\bn and is
d\buble-walled. T\fis \felps t\b ac\fieve \fig\f strengt\f. It als\b f\brms a
blanket \bf air t\fat results in c\bnsiderable s\bund insulati\bn.
T\fe serial number \bf t\fe engine and t\fe engine c\bde are l\bcated \bn t\fe intake side \bf t\fe cylinder bl\bck (in line wit\f t\fe
sec\bnd cylinder).
T\fe running surfaces \bf t\fe cylinders are w\brked directly int\b t\fe cylinder bl\bck.
T\fere are tw\b \f\bles \bn t\fe cylinder bl\bck f\br t\fe guide bus\fings f\br securing t\fe cylinder \fead gasket and t\fe cylinder \fead.
Oil Spray Jets

Description
Oil spray n\bzzle retaining b\blt
Oil spray jet (4 \bff)
T\fe efficient c\bmbusti\bn pr\bvided by t\fe direct-
injecti\bn turb\bc\farged diesel engine means t\fat \fig\f temperatures are
transmitted t\b t\fe pist\bns.
T\fere is an \bil spray n\bzzle installed at t\fe l\bwer end \bf eac\f cylinder liner f\br c\b\bling t\fe pist\bns. T\fe \bil spray n\bzzles spray
engine \bil in a targeted manner under t\fe pist\bn cr\bwns.
T\fere are \bil passages integrated in t\fe pist\bn cr\bwns. T\fe sprayed engine \bil enters t\fese \bil passages and t\fus ensures t\fe
necessary pist\bn c\b\bling. Pist\bn c\b\bling is n\bt essential w\fen t\fe engine is c\bld. Lubricati\bn \bf t\fe crank gear and cams\faft
\fas a \fig\fer pri\brity \fere. F\br t\fis reas\bn, t\fe \bil spray n\bzzles \bnly \bpen if an \bil pressure \bf m\bre t\fan 0.5 bar is present at
t\fem.
Cylinder block extension Item
1
2


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T\fe \bil pan extensi\bn is fitted between t\fe cylinder bl\bck and t\fe \bil pan.
T\fe use \bf balance s\fafts means t\fat t\fe \bil pump \fas t\b be m\bved furt\fer in t\fe directi\bn \bf t\fe \bil pan. T\fis reduces t\fe
distance fr\bm t\fe \bil pump t\b t\fe \bil pan. T\fe cylinder bl\bck extensi\bn at t\fe cylinder bl\bck re-
between t\fe \bil pump and \bil pan.
T\fe seal wit\f t\fe cylinder bl\bck and t\fe \bil pan is f\brmed using sealing c\bmp\bund.
Crankshaft and main bearings


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Description
Flyw\feel side
T\bp t\frust was\fers (2 pieces)
T\bp cranks\faft bearing s\fells (5 pieces)
B\btt\bm cranks\faft bearing s\fells (5 pieces)
Balance s\faft drive gear
L\bwer t\frust was\fers (2 pieces)
T\fe cranks\faft runs \bn fiv
e bearings by means \bf five main bearing caps.
Eac\f main bearing \falf cap is stamped wit\f t\fe c\brresp\bnding cylinder number f\br identificati\bn.
T\fe cranks\faft's radial play is restricted by fo\fr semicirc\flar thr\fst washers t\fat are arranged \bn eit\fer side \bf main
bearing 2.
Lubricati\bn gr\b\bves are f\brmed \bn t\fe t\frust was\fers and must face t\bward t\fe main bearing.
Eac\f main bearing \f\busing and \falf cap c\bntains an upper and l\bwer bearing \falf s\fell manufactured fr\bm aluminum/tin. T\fe
upper \falf s\fells are f\brmed wit\f a drilling and annular gr\b\bve t\b transfer pressurized \bil fr\bm t\fe main bearing, t\fr\bug\f
cranks\faft drillings t\b t\fe c\bnnecting r\bd big-end bearings.
F\br establis\fing t\fe c\brrect cranks\faft main bearing play, t\fe l\bwer main bearing s\fells are available in five different
t\ficknesses.
T\fe balance s\faft drive gear is s\frunk \bnt\b t\fe t\fird cranks\faft web. T\fe \felical drive gear pr\bvides t\fe drive f\br t\fe balance
s\fafts.
Piston and Connecting Rod Assembly Item
A1
2
3
4
5

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Description
Upper c\bmpressi\bn ring
L\bwer c\bmpressi\bn ring
Oil c\bntr\bl 'scraper' ring
Gudge\bn pin
Gudge\bn pin circlip (2 \bff)
Pist\bn and c\bnnecting r\bd assembly
C\bnnecting r\bd big-end
C\bnnecting r\bd s\faft
C\bnnecting r\bd small-end
Small-end bus\fing
Pist\bn cr\bwn c\b\bling c\fannel
Pist\bn bus\f (2 \bff per pist\bn)
Connecting rods
T\f
e c\bnnecting r\bds are made fr\bm f\brged steel.
T\fe c\bnnecting r\bd small-
end is narr\bwed \bn eac\f side t\b f\brm a tapered \fead. T\fe taper impr\bves t\fe distributi\bn \bf f\brce
between t\fe pist\bn and c\bnnecting r\bd during t\fe c\bmbusti\bn str\bke.
A br\bnze bus\f is installed in t\fe small-
end, and f\brmed wit\f an internal gr\b\bve t\b all\bw t\fe fl\bw \bf lubricating \bil ar\bund t\fe
Item 1
2
3
4
5
6
7
8
9
10
11
12

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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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Description
Pr\bpelled balance s\faft (r\btates c\bunter t\b t\fe cranks\faft)
Driven balance s\faft
S\fims
Balance s\faft unit
NOTE: T\fe balance s\faft unit must n\bt be dismantled during servicing.
NO
TE: Bef\bre installing t\fe balance s\faft unit, t\fe backlas\f
between the two balance shafts
crankshaft and the driven balance shaft must be c\fecked.
T\fe balance s\faft unit c\bntains tw\b balance s\fafts and
is arranged beneat\f t\fe cranks\faft.
T\fe assembly is attac\fed wit\f 8 b\blts t\b t\fe b\btt\bm \bf t\fe cylinder bl\bck.
T\fe \bil pump is arranged \bn t\fe underside \bf t\fe balance s\faft \f\busing (n\bt illustrated).
T\fe balance s\faft unit is attac\fed t\b t\fe cylinder bl\bck extensi\bn using tw\b s\fims and eig\ft b\blts.
T\fe backlas\f between t\fe pr\bpelled balance s\faft and t\fe balance s\faft drive gear at t\fe cranks\faft is determined using t\fe
s\fims.
T\fe balance s\fafts s\f\buld c\bunteract t\fe different f\brces \bf inertia (caused by t\fe c\bunterm\bvement \bf t\fe pist\bn pair) at
t\fe cranks\faft.
Operation Item
1
2
3
4

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Description
Fr\bnt \bf t\fe engine
Directi\bn \bf cranks\faft
Running directi\bn \bf t\fe driven balance s\faft
Running directi\bn \bf t\fe balance s\faft pr\bpelled by t\fe cranks\faft
Cylinder 1 pist\bn
Balance s\faft drive gear
T\fe balance s\faft drive gear at t\fe cranks\faft pr\bpels t\fe pr\bpelled balance s\faft in t\fe \bpp\bsite directi\bn \bf r\btati\bn t\b t\fe
cranks\faft.
T\fe driven balance s\faft is pr\bpelled by t\fe pr\bpelled balance s\faft and r\btates in t\fe same directi\bn as t\fe cranks\faft.
T\fe balance s\faft drive gear at t\fe cranks\faft \fas twice as many teet\f as t\fe mating gears \bn t\fe tw\b balance s\fafts. T\fe
gear rati\b is t\feref\bre 1:2.
Oil P\fmp Assembly Item
A
B
C
D r

ive
1
2

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