FORD GALAXY 2006 Service Repair Manual

I\fst\bll\btio\f
DW,\fEmission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
1. NOTE:\f\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\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 - I\ft\bke Air Shutoff
Throttle
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
I\fst\bll\btio\f 1. \f
2.
CAUTION:\f
M\bke\fsure\f
th\bt\fthe\finside\f
of\fthe\fpipe\f
ends\f\bre\fcle\bn\f
\bnd\ffree\fof\foil\f
residue.\f
NOTE:\fThe\f
se\bl\fis\fto\fbe\f
reused\funless\f
d\bm\bged.\f
1.Torque:\b
Nm\f
2.
Torque:\b
Nm\f
3.
Torque:\b
Nm\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.2L
Dur\btorq-TDCi (129kW/175PS) - DW -
Fuel R\bil
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f B\bt
tery\fDisconnect\f\bnd\fConnect\f(414-
01\f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
Refer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-00\fGener\bl\fInform\btion,\f
De s

cription\f\bnd\fOper\btion).\f
Refer\fto:\f Air\fCle\bner \f(303-12F\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
2. CAUTIONS:\f
M\b ke\fsure\fth\bt\fthe\ffuel\fline\frem\bins\fin\f
cont\bct\f\bt\fboth\fends\funtil\fboth\funions\fnuts\f
h\bve\fbeen\funscrewed\f\bnd\fthe\f\bre\b\f\bround\f
the\fjoints\fthoroughly\fcle\bned.\f\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f\f
Refer\fto:\f Fu
el\fInjection\fComponent\fCle\bning\f
(30
3-04F\fFuel\fCh\brging\f\bnd\fControls\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fGener\bl\f
Procedures).\f
Torque:\b \f
22\fNm
\f
25\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
3. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
4. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in

st\blled.\f\f
Torque:\b 1:
\f10\fNm
\f
2:\f8\fNm
\f
3:\f10\fNm
\f
5. Torque:\b 8\fNm
\f
\f\f
\f\f
\f\f
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I\fst\bll\btio\f 6.
CAUTIONS:\f
Us

e\f\bn\fopen-ended\fwrench\fto\fprevent\f
the\fcomponent\ffrom\fturning.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f\f
M\bke\fsure\fth\bt\fthe\f\bre\b\f\bround\fthe\f
component\fis\fcle\bn\f\bnd\ffree\fof\fforeign\f
m\bteri\bl.\f
NOTE:\fInst\bll\f\bll\fthe\fbolts\ffinger\ftight\fbefore\f
fin\bl\ftightening.\f\f 1. Torque:\b 8
\fNm\f
2. Torque:\b \f
22\fNm
\f
25\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
7. Torque:\b 18\fNm\f
8. \f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.2L
Dur\btorq-TDCi (129kW/175PS) - DW -
Fuel I\fjectors
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f Di
esel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre
c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
Refer\fto:\f Int\bke\fM\bnifold\f(303-01G\fEngine\f-
\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. Cle\bn\fthe\ffuel\finjectors,\ffuel\fr\bil,\fhigh-pressure\f fuel\fsupply\flines\f\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(30

3-04F\fFuel\fCh\brging\f\bnd\fControls\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fGener\bl\f
Procedures).\f
3. \f
4. CAUTIONS:\f
M\b

ke\fsure\fth\bt\fthe\ffuel\fline\frem\bins\fin\f
cont\bct\f\bt\fboth\fends\funtil\fboth\funions\fnuts\f
h\bve\fbeen\funscrewed\f\bnd\fthe\f\bre\b\f\bround\f
the\fjoints\fthoroughly\fcle\bned.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f
Disc\brd\fthe\fhigh-pressure\ffuel\fsupply\flines.\f
5. \f
6. \f
\f\f
\f\f
\f\f
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I\fst\bll\btio\f 7. \f
1
. N

OTE:\fM\bke\fsure\fth\bt\fnew\fcomponents\f\bre\f
i n

st\blled.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fse\bl\fis\fcorrectly\f
loc\bted.\f
2. NOTE:\fInst\bll\f\bll\fthe\fbolts\ffinger\ftight\fbefore\f
f
i

n\bl\ftightening.\f
Torque:\b \f
5\f
Nm
\f
130
°\f
St\bge\f1:\f
St\bge\f2:\f
3. \f
4. Torque:\b \f
22\fNm
\f
25\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
\f\f
\f\f
\f\f
\f\f
\f\f
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5. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.2L
Dur\btorq-TDCi (129kW/175PS) - DW -
Fuel Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
1.NOTE:\fV\bcuum\f\bny\fforeign\fm\bteri\bl\ffrom\fthe\f
fu

el\fpump\f\bnd\ffuel\fr\bil\funions\fbefore\fse\bling\f
the\funions\fwith\fbl\bnking\fc\bps.\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\f
cont\bin\finst\bll\btion\fdet\bils.\f
Refer\fto:\f Di
esel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre
c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. 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
Refer\fto:\f Air\fCle\bner \f(303-12F\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
3. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in
st\blled.\f\f
Torque:\b 1:
\f10\fNm
\f
2:\f8\fNm
\f
3:\f10\fNm
\f
4. Torque:\b 8\fNm
\f
5. CAUTIONS:\f
M\b
ke\fsure\fth\bt\fthe\f\bre\b\f\bround\fthe\f
component\fis\fcle\bn\f\bnd\ffree\fof\fforeign\f
m\bteri\bl.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f\f
Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
6. CAUTIONS:\f
Us e\f\bn\fopen-ended\fwrench\fto\fprevent\f
\f\f
\f\f
\f\f
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I\fst\bll\btio\f the\fcomponent\ffrom\fturning.\f
M\bk

e\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f\f
M\bke\fsure\fth\bt\fthe\f\bre\b\f\bround\fthe\f
component\fis\fcle\bn\f\bnd\ffree\fof\fforeign\f
m\bteri\bl.\f
NOTE:\fInst\bll\f\bll\fthe\fbolts\ffinger\ftight\fbefore\f
fin\bl\ftightening.\f\f 1. Torque:\b 8
\fNm\f
2. Torque:\b \f
22\fNm
\f
25\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
7. \f
8. Torque:\b 22\fNm
\f
9. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n

st\blled.\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.2L
Dur\btorq-TDCi (129kW/175PS) - DW -
Throttle Body
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Torque:\b 1
0\fNm\f
2. Torque:\b 8\fNm
\f
3. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in

st\blled.\f
Torque:\b 1\f
10\fNm
\f
2\f10\fNm
\f
3\f8\fNm
\f
4. \f
5. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
th

e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f Torque:\b 10\fNm
\f
\f\f
\f\f
\f\f
\f\f
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