FORD GALAXY 2006 Service Repair Manual

I\fst\bll\btio\f Vehicles\fbuilt\fup\fto\f07/2007\f
10.
Special\bTool(\f):\b
3
03-249\f
1. Sp
ecial\bTool(\f):\b 205-072\f
To r

que:\b 45\fNm
\f
2. Material:\b Thre\bd\fLocking\fMS\f(WSK-M2G349-A7\f/\f
2U 7

J-M2G349-AA) \f
3. NOTE:\fAccess\fthe\ffuel\fpump\fbolts\fthrough\f
t
h

e\fholes\fprovided.\fThe\fbolts\fc\bnnot\fbe\f
\f\f
\f\f
\f
\f\f
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Vehicles\fbuilt\f10/2007\fonw\brds\f
All\fvehicles\fremoved.\f
Torque:\b
20\fNm
\f
4. Torque:\b 24\fNm
\f
5. \f
6. \f\f 1.Torque:\b 26\fNm
\f
2. Torque:\b 50\fNm
\f
7. Torque:\b 42\fNm
\f
8. Torque:\b 10\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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9.Material:\b Silicone\fSe\bl\bnt\fLB\f(WSE-M4G323-A4\f/\f
2U7J-M4G323-AA) \f
10. M
aterial:\b Thre\bd\fLocking\fMS\f(WSK-M2G349-
A7\f/\f
2U7J-M2G349-AA) \f
11. N
OTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in
st\blled.\f
Disc\brd\fthe\fbl\bnking\fplugs.\f
T o

rque:\bFuel\fpump\fhigh-pressure\ffuel\fsupply\fline\f
union\f25\fNm
\f
Fuel\fr\bil\fhigh-pressure\ffuel\fsupply\fline\f
union\f38\fNm
\f
Fuel\fpump\fbr\bcket\fbolts\f23\fNm
\f
12. Remove\fthe\flint-free\fm\bteri\bl.\f
13. Inst\bll\fthe\ftiming\fbelt.\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
14. Inst\bll\f\b\fnew\ffuel\ffilter\felement.\f
Refer\fto:\f Fuel\fFilter\fElement \f(310-01B\fFuel\fT\bnk\f
\bnd

\fLines\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
\f\f
\f\f
\f\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btorq-TDCi (85kW/115PS) - DW/2.0L
Dur\btorq-TDCi (100kW/136PS) -
DW/2.0L Dur\btorq-TDCi (103kW/140PS)
- DW, Emissio\f Requireme\fts: St\bge IV -
Specific\btio\fs
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Torque Specific\btio\fs
\b) Refer to the relev\b\ft procedure i\f this sectio\f.
ItemNmlb\bftlb\bin
Windshield\fwiper\f\brm\fret\bining\fnuts1511-
Fuel\ffilter\fcr\bsh\fprotection\fshield\fret\bining\fbolts9-80
Fuel\ffilter\fsupport\fbr\bcket\fret\bining\fbolts9-80
High-pressure\ffuel\finjection\fsupply\fpipe\funions\f2317-
Fuel\finjection\fsupply\fm\bnifold\fret\bining\fbolts2216-
Int\bke\fm\bnifold\fret\bining\fbolts9-80
Timing\fbelt\fupper\fcover\fret\bining\fbolts7-62
Fuel\finjector\fret\bining\fbr\bcket\fnuts\b--
Fuel\fpump\fret\bining\fbolts2015-
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btorq-TDCi (85kW/115PS) - DW/2.0L
Dur\btorq-TDCi (100kW/136PS) -
DW/2.0L Dur\btorq-TDCi (103kW/140PS)
- DW, Emissio\f Requireme\fts: St\bge IV -
Fuel Ch\brgi\fg \b\fd Co\ftrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\f \b\fd Oper\btio\f
Ge\fer\bl Overview
\f\f
Descriptio\f
Fuel\ffilter\fhousing\f
Fuel\finjector(s)\f
Fuel\fpump\f
Fuel\fmetering\fv\blve\f
Fuel\fpressure\fregul\btor\f
High-pressure\ffuel\fsupply\fline(s)\f
Fuel\fr\bil\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
Int\bke\f\bir\fshutoff\fthrottle\f
A\fSiemens\fcommon\fr\bil\fdiesel\finjection\fsystem\fis\fused\fon\fthe\f2.0L\fDur\btorq\fTDCi\f(DW10)\f Item
1
2
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9
\f
P\brt Number -
-
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engine.\f
Within\fthe\ffuel\fpump\fis\f\bn\fintegr\bl\ffuel\ftr\bnsfer\fpump\fwhich\fdelivers\fthe\ffuel\ffrom\fthe\ffuel\f
t\bnk\fto\fthe\ffuel\fpump.\f
A\ffuel\fmetering\fv\blve\fis\floc\bted\fin\fthe\ffeed\fport\fto\fthe\fhigh-pressure\fch\bmber\fof\fthe\ffuel\f
pump.\fThe\ffuel\fmetering\fv\blve\fv\bries\fthe\fqu\bntity\fof\ffuel\fsupplied\fto\fthe\ffuel\fpump\f
elements,\fin\f\bccord\bnce\fwith\fdriving\fconditions.\f
At\fhigh-pressure,\fthe\ffuel\fis\fsent\fto\fthe\ffuel\fr\bil\f\bnd\fthen\fto\fthe\ffuel\finjectors\fre\bdy\ffor\ffuel\f
injection.\fDepending\fon\fengine\foper\bting\fconditions,\fthe\ffuel\finjection\fpressure\fv\bries\f
between\f\bpproxim\btely.\f350\fb\br\f\bnd\f1650\fb\br.\f
Fuel\fpressure\fis\fme\bsured\fusing\f\b\fFRP\fsensor\fon\fthe\ffuel\fr\bil.\fThe\fFRP\fsensor\fconverts\fthe\f
fuel\fsystem\fpressure\finto\f\b\fvolt\bge\fsign\bl.\fThis\fvolt\bge\fsign\bl\f\bcts\f\bs\f\bn\finput\fsign\bl\fto\fthe\f
powertr\bin\fcontrol\fmodule\f(PCM)\ffor\fc\blcul\btion\fof\fthe\fcorrect\ffuel\finjection\fqu\bntity.\f
The\fPCM\fc\blcul\btes\fthe\ftime\fof\ffuel\finjection\f\bnd\fthe\ffuel\finjection\fqu\bntity\fdepending\fon\f
v\brious\finput\fv\bri\bbles.\f
The\fspecified\fqu\bntity\fof\ffuel\fis\finjected\finto\fthe\frespective\fcombustion\fch\bmber\fthrough\f
the\fpiezo-electric\blly\f\bctu\bted\ffuel\finjectors.\fIn\fdoing\fso,\f\b\fpre-injection\f\bnd\f\b\fm\bin\f
injection\foccur\fe\bch\ftime.\f
The\fexcess\ffuel\fis\freturned\fto\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\freturn\fline.\f
The\ffuel\fpressure\fregul\btor\fon\fthe\fhigh-pressure\foutlet\fof\fthe\ffuel\fpump\fregul\btes\fthe\ffuel\f
pressure\f\bnd\fthereby\f\blso\fthe\fpressure\fwithin\fthe\ffuel\fr\bil.\f
Fuel pump
\f\f
Descriptio\f
High-pressure\foutlet\funion\f
Fuel\fpump\ffuel\fsupply\funion\f
Fuel\fmetering\fv\blve\f
Fuel\freturn\funion\f
Fuel\fpressure\fregul\btor\f
The\ffuel\fpump\fis\f\btt\bched\fto\fthe\fcylinder\fhe\bd\fon\fthe\ftr\bnsmission\fside\f\bnd\fis\fdriven\f
d i

rectly\fby\fthe\fexh\bust\fc\bmsh\bft\fthrough\f\b\fdrive\ffl\bnge.\f
Item
1
2
3
4
5
\f
P\brt Number -
-
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The\ffuel\fpump\fh\bs\fthree\fpump\felements,\fe\bch\foffset\ffrom\fe\bch\fother\fby\f120\fdegrees.\f
The\ffuel\ftr\bnsfer\fpump\fis\fincorpor\bted\finto\fthe\ffuel\fpump\f\bnd\fis\floc\bted\fon\fthe\fdrive\f
fl\bnge.\fThe\ffuel\ftr\bnsfer\fpump\fis\f\b\fv\bne\ftype\fpump.\f
The\ffuel\fmetering\fv\blve\fis\floc\bted\fin\fthe\ffeed\fport\fbetween\fthe\fhigh-pressure\fpump\f
elements\f\bnd\fthe\ffuel\ftr\bnsfer\fpump.\fIt\fis\fcontrolled\fby\fthe\fPCM\fusing\fpulse\fwidth\f
modul\btion.\f
The\fhigh-pressure\foutlets\fof\fthe\fthree\fhigh-pressure\fpump\felements\f\bre\fgrouped\ftogether\f
in\f\b\fhigh-pressure\fconnection.\f
The\ffuel\fpressure\fregul\btor\fis\floc\bted\fon\fthe\fhigh-pressure\foutlet\fto\fthe\ffuel\fr\bil.\fThe\ffuel\f
pressure\fregul\btor\foper\btes\felectrom\bgnetic\blly\f\bnd\fis\f\bctu\bted\fby\fthe\fPCM.\f
Fuel r\bil
\f\f
Descriptio\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
The\ffuel\fr\bil\fis\fm\bde\ffrom\fforged\fsteel\f\bnd\fis\f\btt\bched\fdirectly\fto\fthe\fcylinder\fblock.\f
Th

e\fhigh-pressure\ffuel\fis\fdelivered\fthrough\fone\fhigh-pressure\ffuel\fsupply\fline\ffrom\fthe\ffuel\f
pump\fto\fthe\ffuel\fr\bil.\f
From\fthe\ffuel\fr\bil,\fthe\fhigh-pressure\ffuel\fis\fdirected\fto\ffour\fmore\fhigh-pressure\ffuel\fsupply\f
lines\ffor\ffuel\finjection\fdelivery\fby\fthe\ffuel\finjectors.\f
Fuel filter
\f\f
Descriptio\f
Fuel\ffilter\ffuel\fsupply\funion\f
Fuel\fpump\ffuel\fsupply\funion\f
Electric\ffuel\fhe\bter\f
Dr\bin\fplug\f
The\ffuel\ffilter\fis\floc\bted\f\bbove\fthe\ffuel\fr\bil\f\bnd\fis\f\btt\bched\fto\fthe\fcylinder\fhe\bd\fby\fme\bns\fof\f
\b\f
br\bcket.\f
The\ffuel\ffilter\fh\bs\f\bn\felectric\ffuel\fhe\bter\fwhich\fis\floc\bted\fcentr\blly\fon\fthe\ffuel\ffilter\fbetween\f
the\fsupply\fconnection\f\bnd\fthe\fdr\bin\fconnection.\f
The\ffuel\ffilter\fforms\f\b\fsingle\fcomponent\fwith\fthe\fhousing\f\bnd\fc\bn\fonly\fbe\frenewed\f\bs\f\b\f Item
1
I t

em
1
2
3
4 \f\fP\brt Number
-
\f\f
P\brt Number-
-
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complete\funit.\f
The\ffuel\ffilter\f\blso\fh\bs\f\b\fdr\bin\fplug.\fThis\fmust\fbe\fdr\bined\fregul\brly\fin\f\bccord\bnce\fwith\f
m\binten\bnce\finstructions.\f
Fuel i\fjectors
\f\f
Descriptio\f
High-pressure\ffuel\fsupply\funion\f
Electric\bl\fconnector\f
Fuel\finjector\fcl\bmp\f
Copper\fse\bling\fw\bsher\f
Pl\bstic\fguide\fbush\f
Fuel\finjector\ffuel\freturn\fport\f
The\ffuel\finjectors\f\bre\floc\bted\fcentr\blly\fon\fthe\fcylinder\fhe\bd\fupper\fsection\f\bnd\f\bre\f\btt\bched\f
by
\fme\bns\fof\fcl\bmps.\f
The\fguide\fbushes\fin\fthe\fcylinder\fhe\bd\flower\fsection\f\bnd\fthe\fpl\bstic\fguide\fbushes\fon\fthe\f
fuel\finjectors\fm\bke\fsure\fth\bt\fthey\f\bre\fcentred\fproperly.\f
The\ffuel\finjectors\f\bre\fse\bled\foff\ffrom\fthe\fcombustion\fch\bmber\fby\fme\bns\fof\f\b\fcopper\f
se\bling\fw\bsher\floc\bted\fbetween\fthe\ffuel\finjector\f\bnd\fthe\fcylinder\fhe\bd.\fA\fnew\fse\bling\f
w\bsher\fmust\fbe\finst\blled\fwhen\fservicing\fthe\ffuel\finjectors.\f
The\ffuel\freturn\flines\f\bre\f\btt\bched\fto\fthe\ftop\fof\fthe\ffuel\finjector\f\bnd\f\bre\fconnected\fin\fseries.\f
I\ft\bke \bir shutoff throttle Item
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P\brt Number -
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\f\fDescriptio\f
M\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor\f
Int\bke\f\bir\ftemper\bture\f(IAT)\fsensor\f
Int\bke\f\bir\fshutoff\fthrottle\f
The\fint\bke\f\bir\fshutoff\fthrottle\fis\floc\bted\fon\fthe\fint\bke\f\bir\fside\fof\fthe\fint\bke\fm\bnifold.\f
Th

e\fint\bke\f\bir\fshutoff\fthrottle\fis\felectronic\blly\fcontrolled\fby\fthe\fPCM\f\bnd\fis\fused\fto\fcontrol\f
vehicle\fch\br\bcteristics\fwhile\fthe\fengine\fis\fswitched\foff.\fThis\fwill\f\blso\fprevent\fthe\fengine\f
being\fcontinuously\ffuelled\fby\fthe\fengine\foil\f\bfter\fthe\fignition\fkey\fh\bs\fbeen\fturned\fto\f
position\f0.\fThis\fis\f\bchieved\fby\freducing\fthe\fint\bke\f\bir\fthrough\fthe\fint\bke\fm\bnifold.\f Item
1
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3 P\brt Number
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btorq-TDCi (85kW/115PS) - DW/2.0L
Dur\btorq-TDCi (100kW/136PS) -
DW/2.0L Dur\btorq-TDCi (103kW/140PS)
- DW, Emissio\f Requireme\fts: St\bge IV -
Fuel Ch\brgi\fg \b\fd Co\ftrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Ge\fer\bl Equipme\ft
Pri\fciples of Oper\btio\f
Th

e\f2.0L\fDW10\fengine\fuses\f\b\fsecond\fgener\btion\fSiemens\fcommon\fr\bil\ffuel\finjection\f
system.\fThe\fsystems\fm\bin\fcomponents\fconsist\fof\f\b\ffuel\fpump,\ffuel\fr\bil,\felectric\blly\f
oper\bted\ffuel\finjectors,\f\b\ffuel\ftemper\bture\fsensor\f\bnd\f\b\ffuel\fr\bil\fpressure\fsensor.\f
Fuel Pump
\f\f
Descriptio\f
Fuel\fpump\ffuel\fint\bke\f
Fuel\fpump\fhigh-pressure\ffuel\foutlet\f
Fuel\fmetering\fv\blve\f
High-pressure\ffuel\fpump\fch\bmber\f
Fuel\fpump\ffuel\freturn\foutlet\f
High\fpressure\ffuel\fcontrol\fv\blve\f
The\ffuel\fpump\fconsists\fof\f\b\ftr\bnsfer\fpump\f\bnd\f\b\fhigh-pressure\ffuel\fdelivery\fpump.\fThe\f
tr
\bnsfer\fpump\fdr\bws\ffuel\ffrom\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\ffilter\f\bnd\fdelivers\fthe\ffuel\fto\f
the\fthree\fhigh-pressure\ffuel\fpump\fch\bmbers\fthrough\f\b\ffuel\fmetering\fv\blve.\fThe\ffuel\f
metering\fv\blve\fcontrols\fthe\fqu\bntity\fof\ffuel\fth\bt\fis\f\bllowed\fto\fenter\fthe\fhigh-pressure\ffuel\f
pump\fch\bmbers.\fExcess\ffuel\fvolume\fdeveloped\fby\fthe\ftr\bnsfer\fpump\fis\freturned\fto\fthe\ffuel\f
t\bnk.\fThe\ffuel\fmetering\fv\blve\fis\fcontrolled\fby\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM)\fusing\f\b\f
pulse-width\fmodul\bted\fsign\bl.\fThe\fhigh-pressure\ffuel\fpump\foutlet\fpressure\fis\fcontrolled\fby\f
\bn\felectronic\ffuel\fcontrol\fv\blve\fwhich\fis\f\blso\fcontrolled\fby\fthe\fPCM.\f\f
Fuel R\bil
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Item 1
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P\brt Number -
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