engine FORD GALAXY 2006 Service Repair Manual

cr\bnkb\bttery\fc\bble(s).\f\f
REFER\fto:\fB\btterie\f(414-01\fB\btterie,\f
Befestigung\fund\fB\btteriek\bbel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\fAnl\bsssystem\f(303-06\f
Anl\bsssystem\f-\f2.0L\fDur\btorq-TDCi\f(DW)\f
Diesel,\fDi\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brt.Fuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
Int\bke\fAir\fDistribution\f\bnd\f
Filtering\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f
*
Engine\fm\bn\bgement\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f
*
Ignition\fsystem\f
*CHECK\fthe\fignition\fsystem.\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\fVentilspiel\feinstellen\f(303-01\f
Motor\f-\f2.3L\fDur\btec-HE\f(MI4),\fGener\bl\f
Procedures).\f
*
Timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
or\fbroken\f
*CHECK\fthe\ftiming\fch\bin\f\bnd\ftiming\fch\bin\f
sprockets.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\f\f
REFER\fto:\fSteuerkette\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\froughFuel\fsystem\f
*CHECK\fthe\ffuel\fsystem.\f
*
Int\bke\fAir\fDistribution\f\bnd\f
Filtering\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f
*
Restricted\fexh\bust\fsystem.\f*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\fAuspuffsystem\f-\f2.3L\fDur\btec-
HE\f(MI4)\f(309-00\fAuspuffsystem\f-\f
Allgemeine\fInform\btionen\f-\f2.0L\fDur\btec-
HE\f(MI4)/2.3L\fDur\btec-HE\f(MI4),\f
Description\f\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f
*
Ignition\fsystem\fis\ff\bulty\f
*CHECK\fthe\fignition\fsystem.\f
*
Incorrect\fv\blve\ftiming,\f
timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
(303-01\fMotor\f-\f2.3L\fDur\btec-HE\f(MI4))\f
Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
*
Incorrect\fignition\ftiming\f
*CHECK\fthe\felectronic\fengine\fcontrols.\f
*
Noisy\frunningEngine\f\buxili\bry\f
components\floose\for\f
d\bm\bged.\f
*CHECK\fengine\f\buxili\bry\fcomponents\ffor\f
d\bm\bge\for\flooseness.\fCHECK\f\bnd\f\bdjust\f
v\blve\ftiming.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fREFER\fto:\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4))\f Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
*
Noisy\frunning,\f
misfiring,\fb\bckfiring\f
or\fknocking
Incorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
put\fin\fthe\ft\bnk\f(note\fthe\fcountry\fspecific\f
fuel\fspecific\btions).\f
*
W\bter\fin\ffuel\for\ffuel\f
cont\bmin\bted.\f
*CHECK\fthe\ffuel\fsystem\ffor\fw\bter\for\fother\f
cont\bmin\btion.\f
*
Incorrect\fv\blve\ftiming,\f
timing\fch\bin\for\ftiming\f
ch\bin\fsprockets\fd\bm\bged\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fREFER\fto:\f
(303-01\fMotor\f-\f2.3L\fDur\btec-HE\f(MI4))\f
*
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Oil Leaks - Engine
NOTE:\fBefore\frenewing\fg\bskets\for\foil\fse\bls,\fm\bke\fsure\f
th\bt\fthe\fc\buse\fof\fthe\ff\bult\fis\f
cle\brly\fest\bblished.\f
If\fthe\foil\fle\bk\fc\bnnot\fbe\fidentified\fcle\brly\fby\f\b\fvis u
\bl\finspection,\fc\brry\fout\f\bn\fUV\ftest:\f
Ultraviolet (UV) Testing
1. 1.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2

. \b.
Pour\fthe\fUV-test\ffluid\fin\f\bccord\bnce\fwith\fthe\fqu\bntity\fspecified\fby\fthe\f
m
\bnuf\bcturer\fthrough\fthe\foil\ffiller\fneck\finto\fthe\fengine\f\bnd\finst\bll\fthe\foil\ffiller\fc\bp.\f
WARNING:\fVehicles\fwith\fm\bnu\bl\ftr\bns\bxle,\fshift\fthe\ftr\b
ns\bxle\finto\fNeutr\bl.\fF\bilure\fto\f
observe\fthis\finstruction\fc\bn\fle\bd\fto\finjuries.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4

. 4.
Stop\fthe\fengine.\f
N

OTE:\fIf\fno\fle\bk\fis\ffound,\fperform\f\b\fro\bd\ftest.\fDrive\f
the\fvehicle\funder\fdifferent\flo\bds\f\bnd\f
then\fre-check\fthe\fengine\ffor\fle\bks.\f
5. 5.
Check\fthe\fengine\ffor\foil\fle\bks\fusing\f\b\fsuit\bble\fUV\fl\bmp.\f
6

. 6.
Rectify\f\bny\fle\bks\ffound\f\bnd\fcheck\fthe\fengine\ffor\foil\fle\bks.\f
M

easure the compression pressure
Ventilspiel\feinstellen\f(Gener\bl\f
Procedures),\f
Steuerkette\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
Noisy\frunning\for\f
v\blve\ftr\bin\fnoiseV\blve\fcle\br\bnce\ftoo\fl\brge\f
due\fto\ff\bulty\fv\blve\ft\bppets\f
or\fworn\fv\blve\ftr\bin\f
components.\f
*ADJUST\fv\blve\fcle\br\bnce.\f\f
REFER\fto:\fVentilspiel\feinstellen\f(303-01\f
Motor\f-\f2.3L\fDur\btec-HE\f(MI4),\fGener\bl\f
Procedures).\f
*
Timing\fch\bin\fd\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fch\bin.\f\f
REFER\fto:\fSteuerkette\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Timing\fch\bin\fincorrectly\f
tensioned\f
*CHECK\fthe\ftiming\fch\bin\ftension.\fINSTALL\f
\b\fnew\ftiming\fch\bin\fif\frequired.\f\f
REFER\fto:\fSteuerkette\f(303-01\fMotor\f-\f
2.3L\fDur\btec-HE\f(MI4),\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Noisy\frunning\for\f
engine\fnoiseEngine\fcomponents\f
Pistons\f
Piston\frings\f
Connecting\frod\fbig\fend,\f
m\bin\fbe\bring\for\fthrust\f
be\bring\fjourn\bls\f Connecting\frods\fbent\for\f
d\bm\bged.\f
*
-
-
-
-CHECK\fthe\fengine\fcomponents\ffor\fwe\br\f
or\fd\bm\bge.\fM\bke\fsure\f\bll\fcomponents\f\bre\f
within\fspecific\btion.\fINSTALL\f\b\fnew\f
cylinder\fblock\fif\fnecess\bry.\f\f
REFER\fto:\fSpezifik\btionen\f(303-01\fMotor\f
-\f2.3L\fDur\btec-HE\f(MI4),\fSpecific\btions).
\f
*
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1.1.
Remove\fthe\fcentr\bl\fjunction\fbox\fcover.\f
2
. \b.
Det\bch\fthe\fcentr\bl\fjunction\fbox\f(CJB).\f
3

. 3.
Open\fthe\fCJB\f\bnd\fremove\ffuse\f23\f-\ffuel\fpump\frel\by.\f
N

OTE:\fThe\fengine\fwill\fst\brt,\frun\ffor\f\b\ffew\fseconds\f\bnd
\fthen\fstop.\f
4. 4.
St\brt\fthe\fengine.\f
5

. 5.
Det\bch\fthe\fengine\fcover.\f \f
\f
\f\f
\f\f
\f\f
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10.10.
Inst\bll\fthe\fsp\brk\fplugs\fusing\fthe\fspeci\bl\ftool.\f
1
1. 11.
Inst\bll\fthe\fignition\fcoil-on-plug.\f
1

2. 1\b.
Connect\fthe\fignition\fcoil-on-plug\felectric\bl\fconnectors.\f
1

3. 13.
Inst\bll\fthe\fengine\fcover.\f \f
\f
\f\f
\f\f
\f\f
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2.\b.
Remove\fthe\fengine\fundershield.\f
3
. 3.
Pull\foff\fthe\foil\fpressure\fswitch\fconnector.\f
4

. 4.
Remove\fthe\foil\fpressure\fswitch.\f
5

. 5.
Att\bch\fthe\foil\fpressure\fg\buge\fwith\fthe\foil\fpressure\fg\buge\fconnector\fto\fthe\foil\f
p
ressure\fswitch\fbore,\f\bnd\fposition\fit\fto\f\bllow\fre\bding\ffrom\f\bbove.\f
6. 6.
Lower\fthe\fvehicle.\f
7

. NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine\fspeed.\fMe\bsure\fthe\foil\f \f\f
\f\f
\f\f
\f\f
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13.13.
Inst\bll\fthe\fengine\fundershield.\f
1
4. 14.
Lower\fthe\fvehicle.\f
V

alve train analysis - static (engine off)
Remove\fthe\fcylinder\fhe\bd\fcover.\f
Check\f\bll\fv\blve\ftr\bin\fcomponents\ffor\fd\bm\bge\f\bnd\fwe\br.\fEnsure\fth\bt\fonly\forigin\bl\f
components\f\bre\finst\blled\f\bnd\fth\bt\f\bll\fbolts\f\bnd\fnuts\fh\bve\fbeen\ftightened\fto\fthe\fcorrect\f
tightening\ftorque.\f \f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Valve Clearance AdjustmentS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
Special Tool(s)
Mat

erials
General Equipment
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
205-072-02\f
Ad\bpter\ffor\f205-072\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-499\f
Socket,\fSp\brk\fPlug\f
303-748\f
Locking\fTool,\fCr\bnksh\bft\f
NameSpec\bf\bcat\bo\f
Hypoid\fOil\f85W-90SQ-M2C9002-AA\f/\fA72SX-19K261-CA
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Thre\bd\fLocking\fMSWSK-M2G349-A7\f/\f2U7J-M2G349-AA
Schlitzschr\bubendreher 1.General \bqui\fment: Schlitzschr\bubendreher \f
2. \f
3

. \f
\f
\f
\f
\f
\f
\f\f
\f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Intake ManifoldS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
General Equipment
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Schlitzschr\bubendreher
Trolley\fj\bck
1.General \bqui\fment: Schlitzschr\bubendreher \f
2. \f
3

. Refer\fto:\f Air\fCle\bner\f(303-12A\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
5. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
6. \f
7. \f\f 1.Torque: 48\fNm
\f
2. Torque: 80\fNm
\f
\f\f
\f\f
\f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Crankshaft Front SealS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
In

stallation
303-293\f
Remover,\fCr\bnksh\bft\fSe\bl\f
303-509\f
Remover,\fVibr\btion\fD\bmper\fHub
\f
1. Refer\fto:\f Cr\bnksh\bft\fPulley \f(303-01C\fEngine\f-\f
2.3
L\fDur\btec-HE\f(118kW/160PS)\f-
\fMI4,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. Special\bTool(\f):\b 303-293\f
3. \f

\f
Disc\brd\fthe\ffriction\fw\bsher.\f
1. C

AUTION:\fM\bke\fsure\fth\bt\f\b\fnew\ffriction\f
w \b

sher\fis\finst\blled.\f
2. Special\bTool(\f):\b 303-509\f
\f
\f
\f\f
\f\f
\f\f
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3. Refer\fto:\fCr\bnksh\bft\fPulley \f(303-01C\fEngine\f-\f
2.3
L\fDur\btec-HE\f(118kW/160PS)\f-
\fMI4,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
\f\f
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