FORD GALAXY 2006 Service Repair Manual

I\fst\bll\btio\f 1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
Стр. 2 из 2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1073607&gu...procarmanuals.com
http://vnx.su

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L EcoBoost SCTi
(149kW/203PS) - MI4 - Turboch\brger -
Compo\fe\ft Loc\btio\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\f \b\fd Oper\btio\f
\f\f
Descriptio\f
TC\f(turboch\brger) \fcool\bnt\foutlet\fline\f
TC\fv\bcuum\f\bctu\btor\f
TC\foil\fsupply\ftube\f
W\bsteg\bte\fcontrol\fsolenoid\f
Recircul\bted\f\bir\fv\blve\f
TC\foil\freturn\ftube\f
W\bsteg\bte\fcontrol\fv\blve\f
W\bsteg\bte\fcontrol\fv\blve\fconnecting\frod\f
TC\fcool\bnt\finlet\fline\f
Ite
m
1
2
3
4
5
6
7
8
9
\f
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1263527&gu...procarmanuals.com
http://vnx.su

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L EcoBoost SCTi
(149kW/203PS) - MI4 - Turboch\brger -
Overview
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\f \b\fd Oper\btio\f
Cooli\fg \b\fd lubric\btio\f
Th

e\fTC\f(turboch\brger) \fis\fcooled\fby\fthe\fengine\fcool\bnt\f\bnd\foil\fcircuit.\fThe\f
engine\foil\fcircuit\f
\blso\flubric\btes\fthe\fturbine\fbe\brings.\f
Closed-loop co\ftrol
The\f TC\fis\fcontrolled\fon\fthe\fexh\bust\fside\fby\fthe\fw\bsteg\bte\fc o
ntrol\fv\blve\f\bnd\fon\fthe\fch\brge\f
\bir\fside\fby\fthe\fturboch\brger\fbyp\bss\fv\blve.\fThis\fdouble\fcontrol\fis\frequired\fin\forder\fto\f
\bchieve\foptim\bl\fturboch\brging\f\bnd\foptim\bl\fresponse\funder\f\bll\foper\bting\fconditions.\f
The\fw\bsteg\bte\fcontrol\fv\blve\fis\fclosed\fwhen\fde-energised.\fThe\fentire\fincoming\fflow\fof\f
exh\bust\fg\bs\fflows\fthrough\fthe\fexh\bust\fturbine\f\bnd\fdrives\fit.\fAs\fsoon\f\bs\fthe\fm\bximum\f
permissible\fch\brge\fpressure\fis\fexceeded,\fthe\fw\bsteg\bte\fcontrol\fv\blve\fopens\f\bnd\fguides\f
p\brt\fof\fthe\fflow\fof\fexh\bust\fg\bs\finto\fthe\fexh\bust\fsystem.\f
The\frecircul\bted\f\bir\fv\blve\fensures\fshort-term\f\bdjustments\fto\fthe\fch\brge\fpressure\fon\fthe\f
ch\brge\f\bir\fside.\fSudden\fclosing\fof\fthe\fthrottle\fpl\bte\fc\buses\fb\bckpressure\fin\fthe\fint\bke\ftr\bct\f
between\fthe\fthrottle\fpl\bte\f\bnd\fcompressor\fwheel.\fThis\fresults\fin\fsh\brp\fbr\bking\fof\fthe\f
compressor\fwheel\f\bnd\fthereby\fthe\fturbine\fsh\bft.\fWhen\fthe\fvehicle\fis\f\bcceler\bted\f\bg\bin,\fthis\f
results\fin\f\b\fsignific\bnt\floss\fof\fch\brge\fpressure\for\fpower\f(turbo-hole).\fThe\frecircul\bted\f\bir\f
v\blve\fprevents\fthis\fb\bckpressure\fby\fopening\fthe\fbyp\bss.\fThe\fbyp\bss\fguides\fthe\fch\brge\f
pressure\fb\bck\fto\fthe\fint\bke\fside\fof\fthe\fcompressor.\fThe\fturbine\fspeed\frem\bins\fconst\bnt.\f
The\frecircul\bted\f\bir\fv\blve\fis\fcontrolled\fby\f\b\fv\bcuum\fline.\fThis\fv\bcuum\fline\fis\fconnected\fto\f
the\fint\bke\fm\bnifold\fbetween\fthe\fengine\f\bnd\fthe\fthrottle\fpl\bte.\fWhen\fthe\fthrottle\fpl\bte\fis\f
suddenly\fclosed,\f\bn\fincre\bsed\fv\bcuum\foccurs\fin\fthe\fint\bke\fm\bnifold.\fThis\fc\buses\fthe\f
recircul\bted\f\bir\fv\blve\fto\fopen\fthe\fbyp\bss.\f
Rep\bir \b\fd m\bi\fte\f\b\fce i\fstructio\fs
Oil retur\f tube: If\fthe\fTC\fis\fremoved,\f\b\fnew\f TC\foil\freturn\ftube\fmust\fbe\ffitted\fduring\f
in s

t\bll\btion.\f
Turboch\brger: The\fTC\f\bnd\fthe\fexh\bust\fm\bnifold\f\bre\fone\funit\f\bnd\fmust\fnot\fbe
\fsep\br\bted\f
from\fe\bch\fother.\fIn\fthe\fevent\fof\fd\bm\bge,\fthe\fentire\funit\fmust\fbe\frepl\bced.\f
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1263573&gu...procarmanuals.com
http://vnx.su

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L EcoBoost SCTi
(149kW/203PS) - MI4 - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Ge\fer\bl Equipme\ft
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
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. Refer\fto:\f C\bt\blytic\fConverter \f(309-00B\fExh\bust\f
Sys
tem\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Torque:\b 10\fNm
\f
4. Torque:\b 4\fNm
\f
5. Torque:\b 10\fNm
\f
6. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
7. Torque:\b 4\fNm
\f
\f\f
\f
\f\f
Стр. 1 из
3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1248707&gu...procarmanuals.com
http://vnx.su

8. \f\f1.Genera\f\bEquipment:\b Hose\fcl\bmp\f
rem

over/inst\bller \f
3. To

rque:\b 28\fNm
\f
4. Torque:\b 10\fNm
\f
9. \f\f 1.Genera\f\bEquipment:\b Hose\fcl\bmp\f
rem

over/inst\bller \f
3. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\f
co

mponent\fis\finst\blled.\f
Torque:\b 25\fNm
\f
10. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n

st\blled.\f
Torque:\b 10\fNm
\f
11. Torque:\b 50\fNm
\f
\f
\f\f
\f
\f
Стр. 2 из 3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1248707&gu...procarmanuals.com
http://vnx.su

I\fst\bll\btio\f 1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
Стр. 3 из 3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1248707&gu...procarmanuals.com
http://vnx.su

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.5L Dur\btec
(162kW/220PS) - VI5 - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\f \b\fd Oper\btio\f
Turboch\brger
\f\f
Descriptio\f
Turboch\brger\fint\bke\fpipe\f
Turboch\brger\foutlet\fcooling\fpipe\f
Turboch\brger\f
Turboch\brger\fint\bke\fcooling\fpipe\f
Ch\brge\f\bir\fcooler\fint\bke\fpipe\f
Turboch\brger\foil\freturn\fpipe\f
The\fturboch\brger\fconsists\fof\ftwo\felements,\f\b\fturbine\f\bnd\f\b\fcompressor\fboth\finst\blled\fon\f\b\f
si
ngle\fsh\bft\f\bnd\f\bre\fcont\bined\fwithin\f\b\fturboch\brger\fhousing.\fThe\fturboch\brger\f\bnd\f
exh\bust\fm\bnifold\f\bre\f\b\fcombined\f\bssembly\f\bnd\f\bre\fnot\fsupplied\fsep\br\btely.\f
The\fturboch\brger\fbe\brings\f\bre\fsupplied,\fcooled\f\bnd\flubric\bted\fby\foil\ffrom\fthe\fengine\f
through\fthe\foil\fsupply\ftube.\fOil\fis\freturned\fto\fthe\foil\fp\bn\fthrough\fthe\foil\freturn\fpipe.\fIn\f
\bddition\fthe\fturboch\brger\fis\f\blso\fcooled\fby\fengine\fcool\bnt\fwhich\fis\fsupplied\ffrom\fthe\fengine\f
\bnd\fcooled\fdown\fby\fthe\fr\bdi\btor.\f Item
1
2
3
4
5
6
\f
P\brt Number -
-
-
-
-
-
Стр. 1 из 2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510107&gui...procarmanuals.com
http://vnx.su

The\fturbine\felement\fof\fthe\fturboch\brger\fuses\fthe\fenergy\fof\fthe\fexh\bust\fg\bs\fto\fdrive\fthe\f
compressor.\fThe\fcompressor\fdr\bws\fin\f\bir\ffrom\fthe\f\bir\fcle\bner,\fthrough\fthe\fturboch\brger\f
which\fincre\bses\fpressure\f\bnd\fflow\fof\f\bir.\fTurboch\brged\f\bir\fis\fthen\fforced\fthrough\fthe\f
ch\brge\f\bir\fcooler\fwhere\f\bir\ftemper\bture\fis\fcooled\fbefore\fit\fre\bches\fthe\fint\bke\fm\bnifold.\f
The\fturboch\brger\fboost\fpressure\fis\fgoverned\fby\fme\bns\fof\f\b\fw\bsteg\bte\fcontrol\fv\blve.\fThe\f
w\bsteg\bte\fredirects\fsome\fof\fthe\fexh\bust\fg\bs\fp\bst\fthe\fturbine\fso\fover\fboosting\fdoes\fnot\f
occur.\fThe\fw\bsteg\bte\fcontrol\fv\blve\fis\fcontrolled\fby\f\b\fw\bsteg\bte\fcontrol\fsolenoid\fwhich\fis\f
preset\fduring\fm\bnuf\bcture\f\bnd\fmust\fnot\fbe\ft\bmpered\fwith.\f
Стр. 2 из 2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510107&gui...procarmanuals.com
http://vnx.su

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.5L Dur\btec
(162kW/220PS) - VI5 - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Speci\bl Tool(s)
Ge\f

er\bl Equipme\ft
Pri\fciples of Oper\btio\f
T h

e\fturboch\brger\fis\fgoverned\fby\f\b\fw\bsteg\bte\fcontrol\fv\blve.\fThe\fw\bsteg\bte\fcontrol\fv\blve\f
redirects\fsome\fof\fthe\fexh\bust\fg\bs\fp\bst\fthe\fturbine\f\bnd\ftherefore\f\bcts\f\bs\f\b\fgovernor.\fThe\f
w\bsteg\bte\fcontrol\fv\blve\fis\fpreset\fduring\fm\bnuf\bcture\f\bnd\fmust\fnot\fbe\ft\bmpered\fwith.\f
The\fint\bke\f\bir\fsystem\fis\ffitted\fwith\f\b\fturboch\brger\fpressure\frele\bse\fv\blve.\fThis\fvents\fthe\f
int\bke\f\bir\fsystem\fwhen\fthe\fthrottle\fis\fclosed\f\bnd\frecircul\btes\fthe\f\bir\fb\bck\finto\fthe\fint\bke\f\bir\f
system.\fIt\f\blso\frele\bses\fpressure\fon\fthe\fturboch\brger\fwhich\fwill\freduce\fturbo\fl\bg\f\bnd\fwill\f
improve\f\bcceler\btion\f\bnd\fincre\bse\fengine\fperform\bnce.\f
The\fturboch\brger\fis\fequipped\fwith\f\b\fboost\fcontrol\fsystem.\fThe\fpowertr\bin\fcontrol\fmodule\f
(PCM)\fdetects\f1st\for\f2nd\fge\br\fusing\fthe\fengine\fspeed\f\bnd\fvehicle\fspeed\fsign\bls.\fThis\f
inform\btion\fis\fthen\fused\fto\f\bdjust\fthe\fpressures\f\bpplied\fto\fthe\fw\bsteg\bte\fcontrol\fv\blve\f
\bllowing\fit\fto\fopen\f\bt\f\b\flower\fboost\fpressure.\fThis\fprevents\fthe\fturboch\brger\fdeveloping\f
m\bximum\fboost\fin\f1st\f\bnd\f2nd\fge\brs.\f
I\fspectio\f \b\fd Verific\btio\f
NOTE:\fIt\fis\fnorm\bl\ffor\f\b\fsm\bll\f\bmount\fof\fcombustion\fg \b
s\fto\fp\bss\finto\fthe\fcr\bnkc\bse.\fThis\f
g\bs\fis\fsc\bvenged\finto\fthe\f\bir\fint\bke\fsystem\fthrough\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f
(PCV)\fsystem,\fwhich\fincorpor\btes\f\bn\fcr\bnkc\bse\fvent\foil\fsep\br\btor.\fSome\fengine\foil,\fin\fthe\f
form\fof\f\b\fv\bpor\fis\fc\brried\finto\fthe\f\bir\fint\bke\fsystem\fwith\fthe\fblow-by\fg\bses\f(this\fengine\f
oil\f\blso\fcontributes\fto\fv\blve\fse\bt\fdur\bbility).\fThis\fme\bns\fth\bt\foil\fwill\fcollect\finside\fthe\f\bir\f
int\bke\fcomponents\f\bnd\fthe\fturboch\brger.\fThis\fis\fnot\f\bn\findic\btion\fth\bt\fthe\fturboch\brger\f
oil\fse\bl\fh\bs\ff\biled.\fThe\fturboch\brger\foil\fse\bl\fwill\fnot\ff\bil\funless\fthe\fbe\brings\ff\bil\ffirst,\f
which\fwill\fc\buse\fthe\fturboch\brger\fto\fbecome\fnoisy\for\fseize.\fDo\fnot\finst\bll\f\b\fnew\f
turboch\brger\fdue\fto\foil\finside\fthe\fturboch\brger\for\fthe\f\bir\fint\bke\fcomponents.\fIf\f\b\fle\bk\fis\f
detected\fin\fthe\foil\fsupply\for\freturn\ftubes\for\fconnections,\floc\bte\f\bnd\frectify\fthe\fsource.\fDo\f
not\finst\bll\f\b\fnew\fturboch\brger\fdue\fto\f\bn\foil\fle\bk.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

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

isu\bl I\fspectio\f Ch\brt
Boost\fPressure\fG\buge\f
310-020\f(23-021)\f
H\bnd\fV\bcuum/Pressure\fPump\f
416-D001\f(23-036A)\f
Ford\fdi\bgnostic\fequipment
Mechanica\bE\bectrica\b

Oil\fle\bk(s)\f\f

Cool\bnt\fle\bk(s)\f\f
Wiring\fh\brness(es)\f\f

Electric\bl\fconnector(s)\f\f
\f
\f
Стр. 1 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510108&gui...procarmanuals.com
http://vnx.su

3.3. 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.
If\fthe\fconcern\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f
D
i\bgnostic\fTrouble\fCode\f(DTC)\fIndex.\f
Di\bg\fostic Trouble Code (DTC) I\fdex
Symptom Ch\brt

W\bsteg\bte\fcontrol\fv\blve\f\f

W\bsteg\bte\fcontrol\fv\blve\fv\bcuum\fhose(s)\f\f

Turboch\brger\fhousing\f\f

Air\fcle\bner\felement\f\f

Air\fcle\bner\foutlet\fpipe\f\f

Air\fcle\bner\fint\bke\fpipe\f\f

Turboch\brger\fint\bke\ftube\f\f

Ch\brge\f\bir\fcooler\f\f

Ch\brge\f\bir\fcooler\fint\bke\fpipe\f\bnd\fhoses\f\f

Ch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fhoses\f\f

Ch\brge\f\bir\fcooler\fr\bdi\btor\f\f

V\blve\fcover\foil\fsep\br\btor\f\f

Turboch\brger\foil\fsupply\ftube\f\f

Turboch\brger\foil\freturn\ftube\f
Ch\brge\f\bir\fcooler\fcooling\ff\bn\f\f

Ch\brge\f\bir\fcooler\fcooling\ff\bn\fswitch\f\f

Ch\brge\f\bir\fcooler\fw\bter\fpump\f\f

Boost\fcontrol\fsolenoid\fv\blve\f\f

Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fTC\fescriptionPossib\be SourceAction
P0236Turboch\brger\fboost\fpressure\f
sensor\fcircuit\fr\bnge/perform\bnce\f
concern
Turboch\brger\fboost\f
pressure\fsensorREFER\fto\fengine\fm\bn\bgement\fguided\fdi\bgnostics\fwithin\fthe\f Ford\fdi\bgnostic\fequipment.
P0237Turboch\brger\fboost\fpressure\f sensor\fcircuit\flow\finputTurboch\brger\fboost\fpressure\fsensor\f
circuitREFER\fto\fengine\fm\bn\bgement\fguided\fdi\bgnostics\fwithin\fthe\f
Ford\fdi\bgnostic\fequipment.
P0238Turboch\brger\fboost\fpressure\f sensor\fcircuit\fhigh\finputTurboch\brger\fboost\fpressure\fsensor\f circuitREFER\fto\fengine\fm\bn\bgement\f
guided\fdi\bgnostics\fwithin\fthe\f Ford\fdi\bgnostic\fequipment.
P0243Turboch\brger\fboost\fcontrol\f solenoid\fconcernTurboch\brger\fboost\fcontrol\fsolenoidREFER\fto\fengine\fm\bn\bgement\fdi\bgnostics\fwithin\fthe\fFord\f di\bgnostic\fequipment.
NOTE: The w\bsteg\bte co\ftrol v\blve u\fit is \b fixed p\brt of the turboch\brger \b\fd
c\b
\f\fot be \bdjusted or re\fewed.
SymptomPossib\be SourcesAction
Blue\fsmoke\fwith\f
excessive\f
turboch\brger\f
noiseTurboch\brger\f
compressor\frubbing\f
on\fhousing\fw\blls.\f Turboch\brger\fturbine\f
rubbing\fon\fhousing\f
w\blls.\f
Turboch\brger\f
be\brings\f\bnd\foil\fse\bl
(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\f
or\fd\bm\bged.\f
*
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Blue\fsmoke\f
without\fexcessive\f
turboch\brger\f
noiseBlocked\for\fd\bm\bged\f
v\blve\fcover\foil\f
sep\br\btor.\f
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08B\f
Eng
ine\fEmission\fControl\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\foil\f
return\ftube\fblocked\for\f
d\bm\bged.\f
*
GO\fto\fPinpoint\fTest\f
B.\f\f
*
Стр. 2 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510108&gui...procarmanuals.com
http://vnx.su