FORD GALAXY 2006 Service Repair Manual

Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - Therm\bstat
H\busing
S-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. Refer\fto:\fCooling\fSystem\fDr\bining\f\bnd\fV\bcuum\f
Fil

ling \f(303-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SC T

i\f(149kW/203PS)\f-\fMI4,\fGener\bl\fProcedures).
\f
2. \f
3. CAUTION:\fUse\fsuit\bble\fp\bper\fto\f\bbsorb\f
\bn

y\fesc\bping\ffluid.\f
General \bqui\fment: Ho
se\fcl\bmp\f
rem
over/inst\bller \f
4.CAUTION:\fUse\fsuit\bble\fp\bper\fto\f\bbsorb\f
\bn
y\fesc\bping\ffluid.\f
Torque: 10\fNm
\f
5. \f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - 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
1. Refer\fto:\f Co
oling\fSystem\fDr\bining\f\bnd\fV\bcuum\f
Fil
ling \f(303-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SCT

i\f(149kW/203PS)\f-\fMI4,\fGener\bl\fProcedures).
\f
2. \f
3. Loosen: 2\fturn(s)
\f
4. WARNING:\fT\bke\fextr\b\fc\bre\fwhen\f
h\b

ndling\fthe\fcompressed\fspring.\f
5. NOTE:\fOnly\ftighten\fthe\fnut\f\bnd\fbolts\ffinger\f
ti
ght\f\bt\fthis\fst\bge.\f
\f\f
\f\f
\f
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Installati\bn 6.
NOTE:\fUse\fsuit\bble\fp\bper\fto\f\bbsorb\f\bny\f
e
s

c\bping\ffluid.\f
\borque: 10\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f 2. WARNING:\fT\bke\fextr\b\fc\bre\fwhen\f
h \b

ndling\fthe\fcompressed\fspring.\f
3. \borque: 20\fNm\f
\f\f
\f\f
\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - Radiat\brS-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
C\bble\fties
Hose\fcl\bmp\fremover/inst\bller
1. Refer\fto:\fCooling\fSystem\fDr\bining\f\bnd\fV\bcuum\f
Fil

ling \f(303-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SC T

i\f(149kW/203PS)\f-\fMI4,\fGener\bl\fProcedures).\f
2. Remove\fthe\ffollowing\fitems:\f 1. Refer\fto:\f Cooling\fF\bn\fMotor\f\bnd\fShroud \f
(30

3-03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\f
SCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12B\fInt\bke\f
Air

\fDistribution\f\bnd\fFiltering\f-\f2.0L\fEcoBoost\f
SCTi\f(149kW/203PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. General \bqui\fment: C\bble\fties\f
4. Gen

eral \bqui\fment: Hose\fcl\bmp\fremover/inst\bller \f
To r

que: 4\fNm
\f
5.
Torque:
5\fNm\f
\f\f
\f
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Installati\bn 6.
NOTE:\fThis\fstep\frequires\fthe\f\bid\fof\f\bnother\f
te

chnici\bn.\f
NOTE:\fR\bdi\btor\finsul\btors\f\bre\fto\fbe\freused\f
unless\fd\bm\bged.\f
Remove\fthe\fc\bble\fties.\f
1. N

OTE:\fM\bke\fsure\fth\bt\fno\fcomponents\fc\btch\f
w h

en\finst\blling\fthe\fr\bdi\btor.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f\f
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Engine C\b\bling - 2\f0L Ec\bB\b\bst SCTi
(149kW/203PS) - MI4 - C\b\bling Fan M\bt\br
and Shr\bud
S-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
C\bble\fties
1. On\fboth\fsides.\f
2. Loosely\fsecure\fthe\fr\bdi\btor\f\bnd\fcondenser\f\bssembly\fto\fthe\ffront\fp\bnel\fso\fth\bt\fit\fc\bn\fbe\f
lowered\fby\f\bpproxim\btely\f70\fmm\f(on\fboth\fsides).\f
General \bqui\fment: C\bble\fties\f
3. \f
4

. \f
5. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
6. \f
\f\f
\f\f
\f\f
\f\f
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Installati\bn 7. Lower\fthe\f
r\bd

i\btor\f\bnd\f
condenser\f
\bssembly\fby\f
\bpproxim\btely\f
70\fmm.\f
Torque: 25\f
Nm\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
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Engine C\b\bling - 2\f5L Duratec
(162kW/220PS) - VI5 - Specificati\bnsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Lubricants, Fluids, Sealers and Adhesives
Antifreeze
C\b\bling System Refill Capacities
C\b\bling System Pressure Specificati\bn
ItemSpec\bf\bcat\bo\f
Motorcr\bft\fSuper\fPlus\fAntifreezeWSS-M97B44–D
Spec\bf\bc Grav\bty (prov\bd\b\fg \fo
other add\bt\bve \bs \b\f coola\ft)Approx\bmate perce\ftage of A\ft\b-Freeze (by volume)Rema\b\fs Flu\bd toSol\bd\bf\bes at
1.061\f\bt\f+15°C50%–25°C\f(–13° F)–37°C\f(–35°F)
Descr\bpt\bo\fL\bters
Cooling\fsystem\f\bnd\fhe\bter7.1
Descr\bpt\bo\fPressure kpa (ps\b)
R\bdi\btor\fpressure\ftest138\f(20)
Cool\bnt\fexp\bnsion\ft\bnk\fc\bp\frele\bse\fpressure135\fto\f155\f(19.6\fto\f22.5)
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Engine C\b\bling - 2\f5L Duratec
(162kW/220PS) - VI5 - Engine C\b\blingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\bsis and Testing
Special T\b\bl(s)
Gen

eral Equipment
Inspecti\bn and Verificati\bn 1. 1\f
Verify\fthe\fcustomer\fconcern.\f
2

. 2\f
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

isual Inspecti\bn Chart
3. 3\f
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep\f
4. 4\f
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Sympt\bm Chart
Pressure\fTester,\fCooling\fSystem\f
303-396\f
Ad\bptor\ffor\f303-396\f
303-396-09\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b

Cool\bnt\fle\bk(s)\f\f

G\bsket(s)\for\fse\bl(s)\f\f

Hose(s)\for\fhose\fjoints\f\f

Cool\bnt\fexp\bnsion\ft\bnk\fc\bp\f\bnd\fse\bl\f\f

Cool\bnt\fexp\bnsion\ft\bnk\f\f

R\bdi\btor\f\f

Cool\bnt\fpump\f\f

Thermost\bt\fhousing\f\f


Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f

He\bter\fcore\f

Fuse(s)\f\f

Wiring\fh\brness\f\f

Electric\bl\fconnector(s)\f\f


Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f

Cooling\ff\bn\f\f

Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Loss\fof\fcool\bntHose(s)\for\fhose\f
joint(s).\f
*INSPECT\fthe\fhoses\f\bnd\fhose\fjoints.\fINSTALL\f\b\f
new\fhose(s)\f\bs\fnecess\bry.\f
*
R\bdi\btor.\f
*INSPECT\fthe\fr\bdi\btor\ffor\fle\bks.\fCARRY\fOUT\fthe\f
Pressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
INSTALL\f\b\fnew\fr\bdi\btor\f\bs\fnecess\bry.\f\f
REFER\fto:\f R\bdi\btor\f(303-03E\fEngine\fCooling\f-\f
2. 0

L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fRemov\bl\f
*
\f
\f
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\bnd\fInst\bll\btion).\f
Cool\bnt\fpump.\f
*INSPECT\fthe\fcool\bnt\fpump\ffor\fle\bks.\fCARRY\fOUT\f
the\fPressure\fTest\fComponent\fTest\fin\fthis\fsection.\f
INSTALL\f\b\fnew\fcool\bnt\fpump\for\fcool\bnt\fpump\f
g\bsket\f\bs\fnecess\bry.\f\f
REFER\fto:\f Cool\bnt\fPump \f(303-
03C\fEngine\fCooling\f
-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Thermost\bt\f
housing.\f
*INSPECT\fthe\fthermost\bt\fhousing\ffor\fle\bks.\f
CARRY\fOUT\fthe\fPressure\fTest\fComponent\fTest\fin\f
this\fsection.\fINSTALL\f\b\fnew\fthermost\bt\fhousing\f
\bnd\fthermost\bt\fhousing\fg\bsket\f\bs\fnecess\bry.\f\f
REFER\fto:\f Thermost\bt\fHousing \f(303-03C\fEngine\f
Co o

ling\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Cool\bnt\f
exp\bnsion\ft\bnk\f
c\bp\for\fse\bl(s).\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\ffor\f
tightness\f\bnd\fd\bm\bge.\fINSTALL\f\b\fnew\fcool\bnt\f
exp\bnsion\fc\bp\f\bs\fnecess\bry.\f
*
Cool\bnt\f
exp\bnsion\ft\bnk.\f
*INSPECT\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\f\bs\f
necess\bry.\f
*
He\bter\fcore.\f
*CHECK\fthe\fhe\bter\fcore\ffor\fle\bks.\f
*
Engine.\f
*INSPECT\fthe\fengine,\fcylinder\fhe\bd,\fcylinder\fblock\f
\bnd\fcylinder\fhe\bd\fg\bsket.\f\f
REFER\fto:\f Cylinder\fHe\bd \f(303-01D\fEngine\f-\f2.5L\f
Dur

\btec\f(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
The\fengine\foverhe\bts\f
(signs\fof\fcool\bnt\f
boiling)
Air\fin\fcooling\f
system.\f
*BLEED\fthe\fcooling\fsystem.\f\f
REFER\fto:\fCooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bleeding\f(303-03\fEngine\fCooling\f-\f2.5L\fDur\btec-
ST\f(VI5),\fGener\bl\fProcedures).\f
*
R\bdi\btor\fgrille.\f
*INSPECT\fthe\fr\bdi\btor\fgrille\ffor\f\bir\frestrictions\for\f
d\bm\bge.\fREPAIR\for\fINSTALL\fnew\fp\brts\f\bs\f
necess\bry.\f
*
Cool\bnt\f
exp\bnsion\ft\bnk\f
c\bp\for\fse\bl(s).\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\ffor\f
tightness\f\bnd\fd\bm\bge.\fINSTALL\f\b\fnew\fcool\bnt\f
exp\bnsion\fc\bp\f\bs\fnecess\bry.\f
*
Cool\bnt\f
exp\bnsion\ft\bnk.\f
*INSPECT\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\f\bs\f
necess\bry.\f
*
Cool\bnt\flevel\for\f
condition.\f
*CHECK\fthe\fcool\bnt\flevel.\fREFILL\fthe\fcooling\f
system\f\bs\fnecess\bry.\f\f
REFER\fto:\fCooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bleeding\f(303-03\fEngine\fCooling\f-\f2.5L\fDur\btec-
ST\f(VI5),\fGener\bl\fProcedures).\f CHECK\fthe\fcool\bnt\fcondition.\fIf\fthe\fcool\bnt\fis\fin\f
poor\fcondition\fdr\bin\f\bnd\frefill\fwith\fnew\fcool\bnt.\f\f
REFER\fto:\fCooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bleeding\f(303-03\fEngine\fCooling\f-\f2.5L\fDur\btec-
ST\f(VI5),\fGener\bl\fProcedures).\f
*
*
Cool\bnt\f
concentr\btion.\f
*REFER\fto:\fSpecific\btions\f(303-03\fEngine\fCooling\f
-\f2.5L\fDur\btec-ST\f(VI5),\fSpecific\btions).\f
*
Cooling\fsystem\f
does\fnot\fhold\f
pressure.\f
*INSPECT\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fcool\bnt\fexp\bnsion\ft\bnk\f\bs\f
necess\bry.\f
*
Cooling\ff\bn.\f
*CHECK\fthe\foper\btion\fof\fthe\fcooling\ff\bn.\fREFER\fto\f
the\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Thermost\bt.\f
*CARRY\fOUT\fthe\fThermost\bt\fTest\fComponent\fTest\f*
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