cooling FORD GALAXY 2006 Service Repair Manual

Radiat\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(303-03E\fEngine\fCooling\f-\f2.0L\fDur\btorq-TDCi\f(85kW/11
5PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
C\b\blant Expansi\bn Tank Cap Pressure Test
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fexp\bnsion\ft\bnk\f
c \b

p\fwith\f\b\fthick\fcloth\fto\fprevent\fthe\fpossibility\fof\fcool\bnt\fsc\blding,\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\fperson\bl\finjury.\f
1. 1\f
Remove\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
2

. 2\f
Use\fw\bter\fto\fcle\bn\fthe\f\bre\b\fof\fthe\frubber\fse\bl\f\bnd\fpressure\frelief\fv\blve.\fInst\bll\fthe\f
p
ressure\ftester\f\bnd\f\bd\bpter\f\bnd\fimmerse\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fin\fw\bter\f.\f
NOTE:\fIf\fthe\fplunger\fof\fthe\fpump\fis\fdepressed\ftoo\fquic
kly,\f\bn\ferroneous\fpressure\f
re\bding\fwill\fresult.\f
3. 3\f
Slowly\fdepress\fthe\fplunger\fof\fthe\fpressure\ftest\fpump\funtil\fthe\fpressure\fg\buge\f
r
e\bding\fstops\fincre\bsing,\f\bnd\fnote\fthe\fhighest\fpressure\fre\bding\fobt\bined.\f
4. 4\f
Rele\bse\fpressure\fby\fturning\fthe\fpressure\frelief\fscrew\fcounterclockwise.\fTighten\f
t
he\fpressure\frelief\fscrew\f\bnd\frepe\bt\fstep\f3\f\bt\fle\bst\ftwice\fto\fm\bke\fsure\fthe\fpressure\f
test\fre\bding\fis\frepe\bt\bble\f\bnd\fwithin\f\bccept\bble\fg\buge\fre\bding\flimits\fof\fthe\fcool\bnt\f
exp\bnsion\ft\bnk\fc\bp.\f
5. 5\f
If\fthe\fpressure\ftest\fg\buge\fre\bdings\f\bre\fnot\fwithin\fthe\f\bccept\bble\fg\buge\fre\bding\f
l
imits,\fINSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
Therm\bstat Test
1. 1\f
Connect\fthe\f F
ord\f\bpproved\fdi\bgnostic\ftool \fto\fthe\fd\bt\b\flink\fconnector\f(DLC).\f
2. 2\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fd\bt\blogger\ffunction,\fSELECT\fthe\ffollowing\f
s
ensors\f(\bs\f\bpplic\bble\fto\fthe\f\bpplic\btion):\f

IAT\f-\fint\bke\f\bir\ftemper\bture\f(IAT)\fsensor\f\f

ECT\f-\fengine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f\f

CHT\f-\fcylinder\fhe\bd\ftemper\bture\f(CHT)\fsensor\f\f

LOAD\f-\fengine\flo\bd\f\f

VSS\f-\fvehicle\fspeed\fsensor\f(VSS)\f\f

RPM\f-\fengine\fspeed\f\f

DSRPM\f-\fdesired\fengine\fspeed\f
The\fIAT\fsensor\foutput\fis\fuseful\fif\fthe\fengine\fbeing\ftested\fis\fcold\for\f\bfter\f\bn\fover-night\fcold\f
so
\bk.\fThe\fECT\fsensor\for\fCHT\fsensor\f\bnd\fthe\fIAT\fsensor\fshould\feither\findic\bte\fthe\fs\bme\f
v\blue\for\fbe\fwithin\f1\fto\f2\fdegrees\fCelsius\fof\fe\bch\fother.\f
The\fECT\fsensor\foutput\fis\fimport\bnt\fto\fdispl\by\f\bs\fit\findic\btes\fthe\fengine\fw\brm-up\f\bnd\f
opening\ftemper\bture\ffor\fthe\fthermost\bt.\fIt\fwill\finiti\blly\findic\bte\f\b\fslightly\fhigher\fre\bding\f
Стр. 4 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510017&gui...procarmanuals.com
http://vnx.su

just\fbefore\fthe\fthermost\bt\fopens\f\bnd\fthen\fdrops\fb\bck\fbefore\fsettling\fto\f\b\fne\br\ffl\bt\fline\foutput\f(see\fgr\bphic\fbelow).\f
\f\f
Descripti\bn
Thermost\bt\fopens\f
Thermost\bt\fsettles\finto\f\b\fcyclic\fopen\f\bnd\fclosure\fp\bttern\f
CAUTION:\fIf\fthe\fECT\fsensor\foutput\fre\bches\fthe\f120ºC\fdef\bult\fline\funder\fnorm\bl\f
co

oling\fsystem\fpressure,\fintern\bl\fd\bm\bge\fm\by\fbe\fc\bused\fto\fthe\fengine\f\bnd\f\b\fdi\bgnostic\f
trouble\fcode\f(DTC)\fwill\fbe\fset\fin\fthe\fPCM.\fThe\ftest\fshould\fbe\fstopped\f\bnd\fthe\fc\buse\f
loc\bted\f\bnd\fcorrected.\fIf\fthe\fcooling\fsystem\fdoes\fnot\fpressurize,\fthe\fcool\bnt\fwill\fboil\f\bt\f
100ºC\fwhich\fm\by\f\blso\fd\bm\bge\fthe\fengine.\fCARRY\fOUT\fthe\fCool\bnt\fExp\bnsion\fT\bnk\fC\bp\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
If\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fonly\f\bllows\fthe\fE
CT\fsensor\fto\fbe\fdispl\byed\fin\fvolts,\f
refer\fto\fthe\ffollowing\ft\bble\ffor\fcorresponding\fCelsius\fv\blues:\f
The\fCHT\fsensor\foutput\fis\fuseful\fto\fex\bmine\fthe\fcylinder\fhe\bd\ftemper\bture\frise\fduring\fthe\f
w\brm-up\fcycle\f\bnd\fl\bter\fduring\fthe\fnorm\bl\flight\fthrottle\fcruise\ftest.\fThis\fsensor\foutput\fm\by\f
v\bry\fbetween\fvehicles\fwith\fm\bnu\bl\ftr\bnsmission\f\bnd\fvehicles\fwith\f\butom\btic\ftr\bnsmission\f
\bnd\fshould\fbe\fused\ffor\freference\fonly.\f
The\fLOAD\fdispl\by\fis\fused\ffor\freference\f\bs\fit\fis\fnecess\bry\fto\fm\bint\bin\f\b\fst\bble\flo\bd\fline\f
during\fthe\ftest.\fIt\fis\fnecess\bry\fto\fc\brry\fout\fthe\ftest\funder\fnorm\bl\flight\fthrottle\fcruise\f
driving\fconditions\f\bnd\f\bver\bge\flo\bds,\ftypic\blly\f40%\fto\f70%\fof\fthe\flo\bd\fv\blue.\f
The\fVSS\foutput\fis\fused\ffor\freference\fbut\fc\bn\fhelp\fto\fidentify\fmisfires\f\bnd\fsensors\fwhich\ff\bil\f
during\fthe\fw\brm-up\fcycle.\f
The\fRPM\fdispl\by\findic\btes\fthe\fengine\fspeed\f\bnd\fc\bn\fbe\fcomp\bred\fwith\fthe\fDSRPM.\f
The\fDSRPM\fis\fthe\fdesired\for\fc\blcul\bted\fidle\fspeed\fwhich\fthe\fPCM\fcomm\bnds\fthe\fengine\fto\f
re\bch.\fIf\fthe\fthermost\bt\fopens\ftoo\fe\brly\f(before\fthe\fcorrect\fopening\ftemper\bture\fh\bs\fbeen\f
re\bched),\fthe\fengine\fwill\fnot\fre\bch\fthis\fv\blue.\f
When\fusing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fd\bt\b\flogger\fmode,\fthe\fsign\bls\frecorded\f
should\frem\bin\fwithin\fthe\fDEFAULT\fv\blues\fset\fby\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
3. WARNING:\fM\bke\fsure\fth\bt\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fis\fpl\bced\fin\fthe\f
v e

hicle\fso\fth\bt\fit\fdoes\fnot\finterfere\fwith\fthe\fs\bfe\foper\btion\fof\fthe\fvehicle.\fDo\fnot\f
pl\bce\fthe\fFord\f\bpproved\fdi\bgnostic\ftool\fin\fthe\fdeployment\fp\bth\fof\f\bny\f\bir\fb\bg.\f
Item
A
B
Vo\btsºCe\bsius
1.3360
1.0270
0.7880
0.6090
0.46100
0.35110
0.27120
\f\f
Part Number -
-
Стр. 5 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510017&gui...procarmanuals.com
http://vnx.su

between\f60ºC\f(140ºF)\f\bnd\f70ºC\f(150ºF),\fthe\fthermost\bt\f\bnd\fits\fse\bling\ffunction\fwithin\fthe\f
thermost\bt\fhousing\fmust\fbe\fchecked.\f5. 5\f
INSTALL\f\b\fnew\fthermost\bt.\f\f
R
EFER\fto:\f Thermost\bt \f(303-03E\fEngine\fCooling\f-\f2.0L\fDur\btorq-TDCi\f
(85

kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
6. 6\f
C\brry\fout\f\bnother\fro\bd\ftest\ffrom\fstep\f1\fusing\fthe\fs\bme\fcriteri\b\fto\fconfirm\fth\bt\fthe\f
c
oncern\fh\bs\fbeen\frectified.\f
7. 7\f
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fcle\br\fthe\fPCM\fkeep\f\blive\fmemory\f(KAM)\f
o
r\felectric\blly\fer\bs\bble\fprogr\bmm\bble\fre\bd\fonly\fmemory\f(EEPROM)\fso\fth\bt\fnew\f
drive\fv\blues\fc\bn\fbe\fle\brnt.\f
Стр. 7 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510017&gui...procarmanuals.com
http://vnx.su

Engine C\b\bling - 2\f2L Durat\brq-TDCi
(129kW/175PS) - DW - Therm\bstatS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installati\bn
Hose\fcl\bmp\fremover/inst\bller 1. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03F\fEngine\fCooling\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fGener\bl\f
Procedures).\f
2. \f
3. General \bqui\fment: Hose\fcl\bmp\f
rem

over/inst\bller \f
4. NOTE:\fThe\fO-ring\fse\bl\fis\fto\fbe\freused\funless\f
d
\b

m\bged\f
General \bqui\fment: Ho
se\fcl\bmp\f
rem
over/inst\bller \f
Tor

que: 8\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
Стр. 1 из
1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1043390&gu...procarmanuals.com
http://vnx.su

Engine C\b\bling - 2\f2L Durat\brq-TDCi
(129kW/175PS) - DW - C\b\blant PumpS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installati\bn 1. Refer\fto:\f
Co
oling\fSystem\fDr\bining,\fFilling\f\bnd\f
Ble
eding \f(303-03F\fEngine\fCooling\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fGener\bl\f
Procedures).\f
2. Refer\fto:\f Timing\fBelt\f(303-01G\fEngine\f-\f2.2L\f
Dur

\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. Torque:\b \f
5\fNm
\f
16\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
1. CAUTION:\fM\bke\fsure\fth\bt\fthe\fm\bting\f
f\b
ces\f\bre\fcle\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1043391&gu...procarmanuals.com
http://vnx.su

(PCV)\fsystem.\f
Worn\for\f
d\bm\bged\fv\blve\f
guide(s),\fpiston\f
ring(s),\fcylinder\f
bore(s),\f
cylinder\fhe\bd\for\f
g\bsket.\f
*
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd,\fpistons\f\bnd\fcylinder\fbores\ffor\f
signs\fof\fwe\br\for\fd\bm\bge.\f\f
REFER\fto:\f Cylinder\fHe\bd\f(303-01A\fEngine\f-\f
2.0

L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
White\fsmokeIncorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\fsuch\f\bs\f
str\bnge\fodors\ffrom\fthe\ffuel\ft\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fg\bsoline.\fINSTALL\f\b\fnew\f
fuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01A\fFuel\fT\bnk\f\bnd\f
Li n

es\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\f
MI4/2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f INSPECT\fthe\ffuel\finjectors.\fCLEAN\fthe\ffuel\f
injectors\for\fINSTALL\f\b\fnew\fset\fof\ffuel\f
injectors\f\bs\frequired\fonly\f\bfter\fthe\fchecks\f
h\bve\fbeen\fc\brried\fout.\f INSTALL\f\b\fnew\ffuel\fr\bil.\fREFER\fto:\f(303-04A\f
Fuel\fCh\brging\f\bnd\fControls\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4)\f Fuel\fR\bil\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4
\f(Remov\bl\f
\bnd\fInst\bll\btion),\f
Fuel\fR\bil\f-\f2.3L\fDur\btec-HE\f
(11
8kW/160PS)\f-\fMI4 \f(Remov\bl\f\bnd\f
Ins

t\bll\btion).\f
*
*
*
*
Cool\bnt\fin\fthe\f
combustion\f
ch\bmber.\f
*CARRY\fOUT\f\b\fcooling\fsystem\fpressure\ftest.\f\f
REFER\fto:\f
Engine\fCooling \f(303-03A\fEngine\f
Coo
ling\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fDi\bgnosis\f\bnd\f
Testing).\f
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd,\fcylinder\fhe\bd\fg\bsket\f\bnd\f
cylinder\fbores\ffor\fwe\br\for\fd\bm\bge.\f\f
REFER\fto:\f Cylinder\fHe\bd\f(303-01A\fEngine\f-\f
2.0

L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Engine\fmisfireEngine\fignition.\f*C\brry\fout\f\bn\fignition\fsystem\fdi\bgnosis\fusing\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Incorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\fsuch\f\bs\f
str\bnge\fodors\ffrom\fthe\ffuel\ft\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fg\bsoline.\fINSTALL\f\b\fnew\f
fuel\ffilter.\f\f
*
*
Стр. 10 из
14
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842046&gui...procarmanuals.com
http://vnx.su

REFER\fto:\fFuel\fFilter\f(310-01A\fFuel\fT\bnk\f\bnd\f
Lin
es\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\f
MI4/2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
INSPECT\fthe\ffuel\finjectors.\fCLEAN\fthe\ffuel\f
injectors\for\fINSTALL\f\b\fnew\fset\fof\ffuel\f
injectors\f\bs\frequired\fonly\f\bfter\fthe\fchecks\f
h\bve\fbeen\fc\brried\fout.\f
INSTALL\f\b\fnew\ffuel\fr\bil.\fREFER\fto:\f(303-04A\f
Fuel\fCh\brging\f\bnd\fControls\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4)\f Fuel\fR\bil\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4
\f(Remov\bl\f
\bnd\fInst\bll\btion),\f
Fuel\fR\bil\f-\f2.3L\fDur\btec-HE\f
(11
8kW/160PS)\f-\fMI4 \f(Remov\bl\f\bnd\f
Ins

t\bll\btion).\f
*
*
Low\ffuel\f
system\f
pressure.\f
*Check\fthe\ffuel\fsystem\fpressure.\f\f
REFER\fto:\f Fuel\fSystem\fPressure\fCheck\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4 \f
(31

0-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
*
EGR\fv\blve\f
sticking\fopen.\f
*REFER\fto:\f(303-08A\fEngine\fEmission\fControl\f
-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-
\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4)\f Engine\fEmission\fControl \f(Di\bgnosis\f\bnd\f
Te s

ting),\f
Engine\fEmission\fControl \f(Di\bgnosis\f\bnd\f
Tes

ting).\f
*
Engine\f
oper\bting\f
temper\bture\f
too\fhigh.\f
*REFER\fto:\f
Engine\fCooling \f(303-03A\fEngine\f
Coo
ling\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fDi\bgnosis\f\bnd\f
Testing).\f
*
ECT\fsensor.\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\fusing\fthe\f
guided\fdi\bgnostic\fmenu\fin\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f
*
CKP\fsensor.\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\fusing\fthe\f
guided\fdi\bgnostic\fmenu\fin\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f
*
CMP\fsensor.\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\fusing\fthe\f
guided\fdi\bgnostic\fmenu\fin\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f
*
KS.\f*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\fusing\fthe\f
guided\fdi\bgnostic\fmenu\fin\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f
*
Fuel\finjectors.\f
*INSPECT\fthe\ffuel\finjectors.\fCLEAN\fthe\ffuel\f
injectors\for\fINSTALL\f\b\fnew\fset\fof\ffuel\f
*
Стр. 11 из
14
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842046&gui...procarmanuals.com
http://vnx.su

(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Positive\f
cr\bnkc\bse\f
ventil\btion\f(PCV)\f
system.\f
*INSPECT\ffor\fvisible\fsigns\fof\fd\bm\bge\f
or\fblock\bge.\fCLEAN,\fREPAIR\for\f
INSTALL\fnew\fp\brts\f\bs\fnecess\bry.\f
*
Worn\for\fd\bm\bged\f
v\blve\fguide(s),\f
piston\fring(s),\f
cylinder\fbore(s),\f
cylinder\fhe\bd\for\f
g\bsket.\f
*
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\f
the\fcylinder\fhe\bd,\fpistons\f\bnd\f
cylinder\fbores\ffor\fsigns\fof\fwe\br\for\f
d\bm\bge.\f\f
REFER\fto:\fCylinder\fHe\bd\f(303-01\f
Engine\f-
\f2.5L\fDur\btec\f(VI5),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
White\fsmokeIncorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\f
such\f\bs\fstr\bnge\fodors\ffrom\fthe\ffuel\f
t\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\f
the\fcomplete\ffuel\fsystem.\fFLUSH\fthe\f
fuel\fsystem\fthrough\fwith\fcle\bn\f
g\bsoline.\fINSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01A\fFuel\f
T\bnk

\f\bnd\fLines\f-\f2.0L\fEcoBoost\fSCTi\f
(149kW/203PS)\f-\fMI4/2.0L\fDur\btec-
HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f
-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f INSPECT\fthe\ffuel\finjectors.\fCLEAN\f
the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f
set\fof\ffuel\finjectors\f\bs\frequired\fonly\f
\bfter\fthe\fchecks\fh\bve\fbeen\fc\brried\f
out.\f INSTALL\f\b\fnew\ffuel\fr\bil.\f\f
REFER\fto:\f Fuel\fR\bil\f(303-04C\fFuel\f
Ch \br

ging\f\bnd\fControls\f-
\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
*
*
*
Cool\bnt\fin\fthe\f
combustion\f
ch\bmber.\f
*CARRY\fOUT\f\b\fcooling\fsystem\f
pressure\ftest.\f\f
REFER\fto:\fEngine\fCooling\f(303-03\f
Engine\fCooling\f-\f2.5L\fDur\btec\f(VI5),\f
Di\bgnosis\f\bnd\fTesting).\f
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\f
the\fcylinder\fhe\bd,\fcylinder\fhe\bd\f
g\bsket\f\bnd\fcylinder\fbores\ffor\fwe\br\for\f
d\bm\bge.\f\f
REFER\fto:\fCylinder\fHe\bd\f(303-01\f
Engine\f-
\f2.5L\fDur\btec\f(VI5),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Engine\fmisfireEngine\fignition.\f
*C\brry\fout\f\bn\fignition\fsystem\f
di\bgnosis\fusing\fthe\fFord\f\bpproved\f
di\bgnostic\ftool.\f
*
Incorrect\for\f
cont\bmin\bted\f
fuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\f
such\f\bs\fstr\bnge\fodors\ffrom\fthe\ffuel\f
t\bnk.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\f
the\fcomplete\ffuel\fsystem.\fFLUSH\fthe\f
fuel\fsystem\fthrough\fwith\fcle\bn\f
*
*
Стр. 9 из
13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842047&gui...procarmanuals.com
http://vnx.su

g\bsoline.\fINSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\fFuel\fFilter\f(310-01A\fFuel\f
T\bnk

\f\bnd\fLines\f-\f2.0L\fEcoBoost\fSCTi\f
(149kW/203PS)\f-\fMI4/2.0L\fDur\btec-
HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f
-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f INSPECT\fthe\ffuel\finjectors.\fCLEAN\f
the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f
set\fof\ffuel\finjectors\f\bs\frequired\fonly\f
\bfter\fthe\fchecks\fh\bve\fbeen\fc\brried\f
out.\f
INSTALL\f\b\fnew\ffuel\fr\bil.\f\f
REFER\fto:\f Fuel\fR\bil\f(303-04C\fFuel\f
Ch \br

ging\f\bnd\fControls\f-
\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
*
Low\ffuel\fsystem\f
pressure.\f
*Check\fthe\ffuel\fsystem\fpressure.\f\f
REFER\fto:\f Fuel\fSystem\fPressure\f
Che

ck\f-
\f2.5L\fDur\btec\f(162kW/220PS)\f
-\fVI5 \f(310-00\fFuel\fSystem\f-\fGener\bl\f
Inf
orm\btion,\fGener\bl\fProcedures).\f
*
Engine\foper\bting\f
temper\bture\ftoo\f
high.\f
*REFER\fto:\fEngine\fCooling\f(303-03\f
Engine\fCooling\f-\f2.5L\fDur\btec\f(VI5),\f
Di\bgnosis\f\bnd\fTesting).\f
*
ECT\fsensor.\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\f
using\fthe\fguided\fdi\bgnostic\fmenu\fin\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
CKP\fsensor.\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\f
using\fthe\fguided\fdi\bgnostic\fmenu\fin\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
CMP\fsensor.\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\f
using\fthe\fguided\fdi\bgnostic\fmenu\fin\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
KS.\f*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\f
using\fthe\fguided\fdi\bgnostic\fmenu\fin\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Fuel\finjectors.\f
*INSPECT\fthe\ffuel\finjectors.\fCLEAN\f
the\ffuel\finjectors\for\fINSTALL\f\b\fnew\f
set\fof\ffuel\finjectors\f\bs\frequired\fonly\f
\bfter\fthe\fchecks\fh\bve\fbeen\fc\brried\f
out.\f
*
FRP\fsensor.\f
*C\brry\fout\f\b\ffull\fengine\fdi\bgnosis\f
using\fthe\fguided\fdi\bgnostic\fmenu\fin\f
Ford\f\bpproved\fdi\bgnostic\ftool.\f
*
Low\fcylinder\f
compression.\f
*CHECK\fthe\fengine\fcompression.\f\f
*
Worn\for\fd\bm\bged\f
v\blve(s),\ft\bppet
(s)\for\fc\bmsh\bft
(s).\f
*
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\f
the\fcylinder\fhe\bd,\fv\blves,\ft\bppets\f
\bnd\fc\bmsh\bfts\ffor\fsigns\fof\fwe\br\for\f
d\bm\bge.\f\f
REFER\fto:\fCylinder\fHe\bd\f(303-01\f
Engine\f-
\f2.5L\fDur\btec\f(VI5),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
D\bm\bged\f
cylinder\fhe\bd\f
*REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\f
the\fcylinder\fhe\bd\fg\bsket\f\bnd\fcylinder\f
*
Стр. 10 из
13
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G842047&gui...procarmanuals.com
http://vnx.su

If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fdiesel.\f\f
REFER\fto:\f Fuel\fT\bnk\fDr\bining \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01A\fFuel\fT\bnk\f\bnd\f
Lin

es\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\f
MI4/2.0L\fDur\btec-HE\f(107kW/145PS)\f-
\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
INSTALL\f\b\fnew\ffuel\fpump,\ffuel\finjectors,\ffuel\f
r\bil,\f\bnd\fhigh-pressure\ffuel\fsupply\flines.\fREFER\f
to:\f(303-04D\fFuel\fCh\brging\f\bnd\fControls\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx)\f
Fuel\fPump \f(Remov\bl\f\bnd\fInst\bll\btion),\f
Fuel\fInjectors \f(Remov\bl\f\bnd\fInst\bll\btion),\f
Fuel\fR\bil\f(Remov\bl\f\bnd\fInst\bll\btion).\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08A\f
Eng
ine\fEmission\fControl\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fDi\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\f
timing.\f
*CHECK\fthe\fv\blve\ftiming.\f\f
REFER\fto:\f Timing\fBelt \f(303-01E\fEngine\f-\f1.8L\f
Dur

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Cool\bnt\fin\fthe\f
combustion\fch\bmber.
\f
*CARRY\fOUT\f\b\fcooling\fsystem\fpressure\ftest.\f\f
REFER\fto:\f Engine\fCooling \f(303-03D\fEngine\f
Co o

ling\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Di\bgnosis\f\bnd\fTesting).\f
REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\fcylinder\f
he\bd,\fcylinder\fhe\bd\fg\bsket\f\bnd\fcylinder\fbores\f
for\fwe\br\for\fd\bm\bge.\f\f
REFER\fto:\f Cylinder\fHe\bd \f(303-01E\fEngine\f-
\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Engine\fmisfire\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshing
DTC\fdetected.\f
*REFER\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Engine\fmisfireLow\ffuel\ft\bnk\flevel.\f
*CHECK\fthe\ffuel\ft\bnk\flevel\fis\fgre\bter\fth\bn\ffour\f
litres.\fIf\fthe\ffuel\ft\bnk\flevel\fis\fless\fth\bn\ffour\f
litres,\fFILL\fwith\ffuel.\f
*
Incorrect\for\f
cont\bmin\bted\ffuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\fsuch\f\bs\f
str\bnge\fodors\ffrom\fthe\ffuel\ft\bnk.\f CHECK\ffor\fsigns\fof\fw\bter\for\fpetrol\fin\fthe\fdiesel.\f
If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fdiesel.\f\f
REFER\fto:\f Fuel\fT\bnk\fDr\bining \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
*
*
*
Стр. 15 из
19
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G504847&gui...procarmanuals.com
http://vnx.su