engine FORD GALAXY 2006 Service Repair Manual

Engine - \b.0L E\foBoost SCTi (149kW/\b03PS) -
MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006
Assembly
Spe\fial Tool(s)
Ma
terials
General Equipment
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
205-072-01\f
Ad\bpter\ffor\f205-072\f
303-1504\f
Alignment\fTool,\fC\bmsh\bft\f
303-499\f
Socket,\fSp\brk\fPlug\f
303-509\f
Remover,\fVibr\btion\fD\bmper\fHub
\f
303-748\f
Locking\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C913-C
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
\b mm pun\fh
Round-ended steel rule 1.
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\finst\blled.
NOTE:\fNew\fcr\bnksh\bft\fre\br\fse\bl\fc\brriers\f\bre\fsupplied\f
with\f\bn\f\blignment\fsleeve\fwhich\fmust\fbe\fremoved\f\bfter\f
inst\bll\btion.\f
Torque:\b10\fNm
\f
2.
CAUTION:\fM\bke\fsure\fth\bt\f\b\fnew\ffriction\fw\bsher\fis\f
inst\blled.\f
\f
\f
\f
\f
\f
\f
\f\f
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Engine - \b.0L E\foBoost SCTi (149kW/\b03PS)
- MI4 - Engine A\f\fessoriesS-MAX/G\bl\bxy\f2006.5\f(02/2006
Installation
Spe\fial Tool(s)
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-254\f
Locking\fTool,\fFlywheel\f
303-397\f
Remover/Inst\bller,\fHose\fCl\bmp
\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
303-435-11A\f
Mounting\fPl\bte\ffor\f303-435-06\f
310-128\f
Inst\bller\fSet,\fTeflon\fSe\bl\f1.CAUTION:\fM\bke\fsure\fth\bt\fnew\fbolts\f\bre\f
in

st\blled.\f
Special\bTool(\f):\b 30
3-254\f
Tor
que:\b 112\fNm
\f
2. \f\f
1.Torque:\b 8\fNm
\f
\f
\f
\f
\f
\f
\f
\f
\f
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Engine - \b.0L E\foBoost SCTi (149kW/\b03PS) -
MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006
Installation
Spe\fial Tool(s)
Ma
terials
General Equipment
205-316A\f
Alignment\fPins,\fSubfr\bme\f
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-735\f
Alignment\fPeg,\fC\bmsh\bft\f
308-720\f
Setting\fG\buge,\fClutch\fCl\bws
\f
308-761\f
Locking\fTool,\fFlywheel\f
NameSpec\bf\bcat\bo\f
Gre\bse\fK-PAGWSA-M1C246-A\f/\f8U7J-M1C246-AA
Hose \flamp remover/installer
Hydrauli\f jib \frane
Mounting table set
Retaining Strap
Transmission ja\fk 1. \f
\f
\f
\f
\f
\f
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57. \f\f1.Torque: 25\fNm
\f
2. Torque: 15\fNm
\f
58. Torque: 12\fNm
\f
59. Torque: 12\fNm
\f
60. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f B\bttery\f(414-
01\fB\bttery,\fMounting\f\bnd\f
C\bbles,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Refer\fto:\f Air\fCle\bner\f(303-
12B\fInt\bke\fAir\fDistribution\f
\bnd\fFiltering\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
61. Refer\fto:\f
Cooling\fSystem\fDr\bining\f\bnd\fV\bcuum\fFilling
03B\fEngine\fCooling\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f
MI4,\fGener\bl\fProcedures).\f
62. \f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - SpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Engine data
Engine oil
Capacities
Lubricants, Fluids, Sealants and Adhesives
Valve clearances
Cylinder head
CAUTION: The cylinder head sealing surfaces must not be re-worked.
Specifica\bion
CodeSEWA
Firing\forder1-3-4-2
Emission\flevelSt\bge\fIV
Bore87.5\fmm
Stroke94\fmm
Engine\fC\bp\bcity2,261\fcm³
Compression\fr\btio10.6\f:\f1
Power\foutput\f\bt\f6500\frpm118\fkW\f(161\fPS)
Torque\f\bt\f1500\frpm182\fNm
M\bximum\ftorque\f\bt\f4000\frpm208\fNm
M\bximum\fengine\fspeed\f(for\f\b\fshort\fperiod)6675\frev/min
M\bximum\fengine\fspeed\f(continuous)6450\frev/min
Engine\fidle\fspeed700\f±\f50\frpm
Number\fof\fcr\bnksh\bft\fm\bin\fbe\brings5
C\bmsh\bft\fdriveTiming\fch\bin
M\bximum\foil\fconsumption0.5\fL/1000\fKm
Vi\fco\fi\by/ambien\b \bempera\bureType\fpecifica\bion
Recommended engine oil
SAE\f5W-30\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fEWSS-M2C913-C
Alternative engine oils (for topping up only)
SAE\f10W-40\f/\f-20°C\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fXR+ACEA\fA3,\fB3
SAE\f5W-40\f/\fbelow\f-20°C\fto\fover\f+40°CFord\fFormul\b\fS/SDACEA\fA3,\fB3
Li\ber\f
Initi\bl\ffill\fincluding\foil\ffilter4.6
Service\ffill\fincluding\foil\ffilter4.3
Service\ffill\fwithout\foil\ffilter3.9
Specifica\bion
Se\bl\bnt,\foil\fp\bn\fcont\bct\fsurf\bce\fto\fcr\bnksh\bft\fre\br\fse\bl\fret\biner,\foil\fp\bn\fto\f
cylinder\fblock,\foil\fp\bn\fto\ffront\fcover,\fengine\ffront\fcover\fto\fcylinder\fblock/\foil\f p\bnWSE-M4G323-
A4
Oil\fpressure\fswitch\f\bnd\fengine\ffront\fcover\fbl\bnking\fplug\fse\bl\bntWSK-M2G349- A7
Specifica\bion
V\blve\fcle\br\bnce\f(engine\fcold)\f-\fint\bke\fv\blves0,22\f-\f0,28
V\blve\fcle\br\bnce\f(engine\fcold)\f-\fexh\bust\fv\blves0,27\f-\f0,33
Specifica\bionmm
M\bximum\fdistortion,\fm\bting\ff\bce0,1
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fescription and Operation
2.3L\fDur\btec-HE\f(MI4)\f
Ap

\brt\ffrom\f\b\ffew\fch\bnges,\fthe\f2.3L\fDur\btec-HE\f(MI4)\fengine\fis\fl\brgely\fb\bsed\fon\fthe\f2.0L\f
Dur\btec-HE\fengine\f\blre\bdy\fused\fin\fthe\fS-MAX/G\bl\bxy\f2006.5\f(03/2006-).\f
Key\ffe\btures\fof\fthe\fengine\finclude:\f

Direct\fignition\fcoils\f\f

Electronic\fthrottle\fv\blve\f\f

Mech\bnic\bl\fthermost\bt\f\f

v\bri\bble\fM\bnifold\fRunner\fControl\f\f

Du\bl-m\bss\fflywheel\f\f

High-perform\bnce\foil\fpump\f
Differences\ffrom\fthe\f2.0L\fDur\btec-HE\f(MI4)\fengine\fv\bri\bnt\ffitted\fto\fthe\fS-
MA

X/G\bl\bxy\f2006.5\f(03/2006-)\fMI4)\f\bre:\f

V\bri\bble\fc\bmsh\bft\ftiming\f(VCT)\f\f

Integr\bl\fdipstick\f\f

B\bl\bnce\fsh\bfts\f
V\bri\bble\fc\bmsh\bft\ftiming\f(VCT)\f
\f
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\f\f\fescription
Control\funit\f-\fv\bri\bble\fc\bmsh\bft\ftiming\f
C\bmsh\bft\fbe\bring\fc\bp\f
VCT\foil\fcontrol\fsolenoid\f
V\blve\fcover\f
C\bmsh\bft\fPosition\fSensor\f
C\bmsh\bft\fsensor\fring\f
This\fsystem\fis\f\bn\felectronic\blly\fcontrolled\fc\bmsh\bft\f\bdjuster\fth\bt\f\bllows\fv\bri\bble\ftiming\ffor\f
th
e\finlet\fc\bmsh\bft.\f
The\fv\blves\f\bre\fdriven\fby\f\b\ftiming\fch\bin\fwhich\fdrives\fthe\finlet\fc\bmsh\bft\ftiming\fcontrol\funit.\f
This\funit\fdrives\fthe\f\bssoci\bted\fc\bmsh\bfts.\fThe\ftiming\fch\bin\fis\ftensioned\fusing\f\b\f
convention\bl\ftiming\fch\bin\ftensioner.\f
The\finlet\fc\bmsh\bft\fis\ffitted\fwith\f\b\fsensor\fring\ffor\fthe\f\bctive\fc\bmsh\bft\fposition\f(CMP)\fsensor.
\f
This\fCMP\fsensor\fis\fmounted\finside\fthe\fv\blve\fcover.\f
Timing\fch\bin\frepl\bcement\fdoes\fnot\frequire\fthe\fv\bri\bble\fc\bmsh\bft\ftiming\fcontrol\funit\fto\fbe\f
disconnected.\f
To\fensure\ftrouble-free\foper\btion\fof\fthe\fv\bri\bble\fc\bmsh\bft\ftiming\fsystem\f\bnd\foptimum\f
engine\fperform\bnce,\fit\fis\fessenti\bl\fto\f\bdhere\fprecisely\fto\fthe\fv\blve\ftiming\f\bdjustment\f
procedure.\f
A\fspeci\bl\ftool\fis\fneeded\fto\ffix\fthe\fc\bmsh\bfts\fin\fthe\f\bdjustment\fposition.\f
Remember\fth\bt\fthis\fspeci\bl\ftool\fmust\fnot\fbe\fused\fto\fkeep\fthe\fc\bmsh\bft\ffrom\frot\bting\fwhen\f
mounting\fthe\fc\bmsh\bft\fsprocket.\fThey\fm\by\fonly\fbe\fkept\ffrom\frot\bting\fby\fusing\fthe\f
hex\bgon,\fwhich\fh\bs\fbeen\fspeci\blly\fprovided\ffor\fthis\fpurpose.\f
Adv\bnt\bges\fof\fv\bri\bble\fc\bmsh\bft\ftiming\f(VCT)\f

Lower\ffuel\fconsumption\fdue\fto\fimproved\fvolumetric\fefficiency\f\f

Enh\bnced\fengine\fpower\f\bnd\ftorque\f\f

Improved\fidling\fch\br\bcteristics\f
I
t

em
1
2
3
4
5
6
\f
Part Number -
-
-
-
-
-
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\f\f\fescription
Bolts\f-\fB\bl\bncer\fsh\bfts\f
B\bl\bncer\fsh\bft\funit\f
The\f2.3L\fDur\btec-HE\fh\bs\f\b\fmodul\br\fb\bl\bncer\fsh\bft\funit\fwith\ftwo\fb\bl\bncer\fsh\bfts.\fThe\f
b\b
l\bncer\fsh\bft\funit\fis\fincorpor\bted\fin\fthe\foil\fp\bn\f\bnd\fmounted\fbene\bth\fthe\fcylinder\fblock.\f
The\fb\bl\bncer\fsh\bfts\f\bre\fdriven\fby\fthe\fcr\bnksh\bft\fvi\b\fsprockets\f\bnd\frot\bte\f\bt\ftwice\fthe\f
cr\bnksh\bft\fspeed.\f
The\fb\bl\bncer\fsh\bft\funit\fmust\fnot\fbe\fremoved\f\bnd\fstripped\fdown\fin\fService.\f
Adv\bnt\bges\fof\fthe\fb\bl\bncer\fsh\bft\funit:\f

Reduces\fthe\f2nd\forder\fforces\fof\finerti\b\f\f

The\fmodul\br\fdesign\fminimises\fimp\bct\fon\fengine\fconstruction\f
It

em
1
2
\f
Part Number -
-
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fiagnosis and Testing
Special Tool(s)
Gen

eral Equipment
Materials
Specification
WSK-M2G349-A7\f\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. \b.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
3

. 3.
Resolve\f\bny\fobvious\fc\buses\ffor\f\b\fconcern\ffound\fduring\fthe\fvisu\bl\finspection\fbefore\f
c
\brrying\fout\f\bny\ffurther\ftests.\f
4. 4.
If\fthe\fconcern\fpersists,\fcheck\fthe\fsymptoms\f\bnd\fcontinue\fwith\fthe\fSymptom\f
C
h\brt.\f
Visual Inspection Chart
Symptom Chart
Symptom chart
Socket,\fSp\brk\fPlug\f
303-499\f
Use\f\b\fcompression\ftester
Name
Adhesive\f-\fLoctite\f243
Mechanica\bE\bectrica\b

Cool\bnt\fle\bks\f\f

Le\bking\foil.\f\f

Fuel\fle\bks\f\f

Visibly\fd\bm\bged\for\fworn\fp\brts\f\f

Loose\for\fmissing\fnuts\for\fbolts\f
Fuse(s)\f\f

Loose\for\fcorroded\fconnector(s)\f\f

Control\funit\f\f

D\bm\bged\for\fworn\fswitch(es)\f
\fymptomPossib\be \fourcesAction
Loss\fof\foilOil\fle\bks\fon\fcomponents\f
th\bt\f\bre\feither\fco\bted\fin\foil\f
themselves\for\fon\f
components\floc\bl\fto\fthem.\f
*CHECK\ffor\fevidence\fof\foil\fle\bks\fon\f
components.\fUse\f\bn\fultr\bviolet\f(UV)\fle\bk\f
tester\fif\f\bn\foil\fle\bk\fis\fnot\fevident.\f
INSTALL\fnew\fg\bskets\for\fcomponents\f\bs\f
required.\f
*
Intern\bl\for\fextern\bl\fle\bk\f\bt\f
the\foil\fcooler.\f
*
CHECK\fwhether\fthere\fis\f\bn\foil\ffilm\fon\fthe\f
cool\bnt\fin\fthe\fcool\bnt\fexp\bnsion\ft\bnk.\f
INSTALL\f\b\fnew\foil\fcooler\for\foil\fcooler\f
se\bl.\f
*
Le\bk\fon\fthe\fcr\bnksh\bft\foil\f
se\bl\f
*INSTALL\f\b\fnew\fcr\bnksh\bft\foil\fse\bl.\fREFER\f
to:\f
Kurbelwellendichtring\fvorn\f(303-01\f
Motor\f-\f2.0L\fDur\btec-HE\f(MI4),\f
Remov\bl\f\bnd\fInst\bll\btion),\f
Kurbelwellendichtring\fhinten\f(303-
01\f
Motor\f-\f2.3L\fDur\btec-HE\f(MI4),\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
\f
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Le\bks\ffrom\foil\fc\brrying\f
components\for\fb\bsic\f
engine.\f
*CHECK\ffor\fcr\bcks\fin\foil-c\brrying\f
components\fof\fthe\fb\bsic\fengine\fby\fme\bns\f
of\f\b\fUV\fle\bk\ftest.\fINSTALL\fnew\f
components\for\fse\bls\f\bs\fnecess\bry.\f
*
Oil\fConsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\f
used\f\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\f
Ch\bnge\fthe\fengine\foil\fto\fthe\fspecific\btion.\f
\f
REFER\fto:\fSpezifik\btionen\f(303-01\fMotor\f
-\f2.3L\fDur\btec-HE\f(MI4),\fSpecific\btions).
\f
*
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f Hoses\for\fventil\btion\for\f
bre\bther\fv\blves\f\bre\f
blocked.\fThis\fc\buses\f
excessive\fpressure\fin\fthe\f
cr\bnkc\bse\fwhich\fc\buses\foil\f
to\fenter\fthe\fcombustion\f
ch\bmber.\f
The\fPCV\foil\fsep\br\btor\fis\f
d\bm\bged.\fOil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\f
m\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\f
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f D\bm\bged\fcylinder\fhe\bd\f
g\bsket\for\fw\brped\fm\bting\f
f\bces.\f Worn\fv\blve\fstem\foil\fse\bls.\f
Engine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f
\bnd\fthe\fv\blve\fguide.\f
*
-
-CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f Remove\fthe\fcylinder\fhe\bd.\fCHECK\fthe\f
condition\fof\fthe\fm\bting\ff\bces\f\bnd\fthe\f
cylinder\fhe\bd\fg\bsket\f\bnd\fCHECK\fthe\f
evenness\fof\fthe\fcylinder\fhe\bd\f\bnd\f
cylinder\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fstem\foil\fse\bls.\f\f
REFER\fto:\fVentilsch\bftdichtringe\f(303-01\f
Motor\f-\f2.0L\fDur\btec-HE\f(MI4),\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
-
-
Piston\fring\for\fcylinder\fliner\f
we\br.\f
*
INSTALL\f\b\fnew\fcylinder\fblock\fif\f
necess\bry.\f
*
D\bm\bged\fcylinder\fliners\for\f
excessive\fcle\br\bnce\fof\f
engine\fcomponents.\f
Pistons\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f
Cylinder\fliners\f
*
-
-
-
CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\f\b\fnew\fcylinder\f
block\fif\fnecess\bry.\f
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f\f
REFER\fto:\fKühlsystem\f(303-03\f
Kühlsystem\f-\f2.0L\fDur\btec-
HE\f(MI4)/2.3L\f
Dur\btec-HE\f(MI4),\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fcooler\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\f
such\f\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
Engine\fwill\fnot\fB\bttery\for\fb\bttery\fc\bble\f
*CHECK\fthe\fb\bttery,\fb\bttery\fholder\f\bnd\f
*
Стр. 2 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G898709&gui...procarmanuals.com
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