FORD GALAXY 2006 Service Repair Manual

Pi\fpoi\ft Tests
Poor\fengine\f
perform\bnce\fW\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f V\bcuum\fline(s).\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Ch\brge\f\bir\fcooler\f
pipes\f Ch\brge\f\bir\fcooler\f
r\bdi\btor\f Ch\brge\f\bir\fcooler\f
w\bter\fpump\f Ch\brge\f\bir\fcooler\f
*
*
*
*REFER\fto\f
in\fthis\fsection. \f
*
Air\fcle\bner\fint\bke\f
pipe\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
w\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fw\bsteg\bte\fcontrol\fv\blve\funit\f\bctu\btor\frod\f
h\bs\fnot\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-
04H\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Ignition\fsystem.\f
*CHECK\fthe\fignition\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\fch\brging\fsystem.\f*CHECK\fthe\ffuel\fch\brging\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\f\bir\fcle\bner.\f\f
REFER\fto:\f
Air\fCle\bner \f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f2
Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No
GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\f1
\f\f
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of\fforeign\fm\bteri\bl.\f
Are\fthere\f\bny\fsigns\fof\fforeign\fm\bteri\bl?\f
Yes CLEAN\fthe\fint\bke\f\bir\fsystem\fcomponents.\fINSTALL\f
\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No
GO\fto\fA3.\f\f
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:\fA\fsm\bll\f\bmount\fof\fmovement\fin\fthe\fbe\brings\fis\fnorm\bl.\f
M\bke\fsure\fthe\fturboch\brger\frotor\fspins\ffreely\f
within\fthe\fhousing.\f

1.\fWith\fthe\fturboch\brger\fst\btion\bry,\fgently\flift\f
th

e\fsh\bft\f(the\fsh\bft\fwill\fn\btur\blly\fl\by\fin\fthe\f
bottom\fof\fthe\fbe\brings).\f

2.\fM\bke\fsure\fthe\frotor\fspins\ffreely\fwithin\fthe\f
ho

using.\f
1
Does\fthe\frotor\fspin\ffreely\fwithin\fthe\fhousing\fwithout\f
excessive\fmovement?\f
Yes GO\fto\fA4.\f\f
No
I

NSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
NOTE:\fDisc\brd\fthe\fcopper\fw\bshers.\f
Disconnect\fthe\foil\fsupply\ftube\ffrom\fthe\f
tu
rboch\brger\f(exh\bust\fm\bnifold\fhe\btshield\f\bnd\f
ch\brge\f\bir\fcooler\fint\bke\fpipe\fshown\fremoved\ffor\f
cl\brity).\f1
NOTE:\fDisc\brd\fthe\fcopper\fw\bshers.\f
Disconnect\fthe\foil\fsupply\ftube\ffrom\fthe\fengine\f\bnd\f
re
move\fthe\foil\fsupply\ftube.\f2
Using\fworkshop\fcompressed\f\bir\f\bnd\f\b\fcompressed\f
\bir\fnozzle\fcheck\fthe\foil\fsupply\ftube\ffor\fblock\bge.\f3
Is\fthe\foil\fsupply\ftube\ffree\ffrom\fblock\bge?\f
Yes
\f\f
\f\f
\f\f
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GO\fto\fA5.\f\f
No I
NSTALL\f\b\fnew\foil\fsupply\ftube.\fINSTALL\f\b\fnew\f
turboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY
Using\fsome\fsuit\bble\fwelding\frod\fcheck\fthe\foil\f
supply\ftube\foil\fg\bllery\ffor\fblock\bge.\f1
Is\fthe\foil\fsupply\ftube\foil\fg\bllery\ffree\ffrom\fblock\bge?\f
Yes
INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No REMOVE\fthe\fblock\bge.\fINSTALL\f\b\fnew\f
turboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER
NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
NOTE:\fDisc\brd\fthe\fg\bsket.\f
Disconnect\fthe\fturboch\brger\foil\freturn\ftube\ffrom\f
th
e\fturboch\brger\f(turboch\brger\fhe\btshield\f\bnd\f
c\bt\blytic\fconverter\fshown\fremoved\ffor\fcl\brity).\f1
NOTE:\fDisc\brd\fthe\fO-ring\fse\bl.\f
Remove\fthe\fturboch\brger\foil\freturn\ftube\f
(t
urboch\brger\fhe\btshield\f\bnd\fc\bt\blytic\fconverter\f
shown\fremoved\ffor\fcl\brity).\f2
\f\f
\f\f
\f\f
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Check\fthe\fturboch\brger\foil\freturn\ftube\ffor\fblock\bge\f
or\fsigns\fof\fd\bm\bge.\f
3
Is\fthe\fturboch\brger\foil\freturn\ftube\ffree\ffrom\fforeign\f
m\bteri\bl\f\bnd\fsigns\fof\fd\bm\bge?\f
Yes GO\fto\fEngine\ffor\ffurther\fdi\bgnostics.\f
REFER\fto:\f Engine\f(303-01D\fEngine\f-\f2.5L\fDur\btec\f
(16

2kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
No INSTALL\f\b\fnew\fturboch\brger\foil\freturn\fpipe,\fg\bsket\f
\bnd\fO-ring\fse\bl.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
PINPOINT TEST C : POOR ENGINE PERFORMANCE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
C1: CHECK THE BOOST PRESSURE
NOTE:\fThe\fboost\fpressure\fis\ff\bctory\fset\f\bnd\fmust\fnot\fbe\f\bdjusted.\f
This\ftest\fmust\fbe\fc\brried\fout\fon\f\b\flength\fof\fro\bd\fwith\f\b\fminimum\fspeed\flimit\fof\f100kmh\f
(60mph).\f
Disconnect\fthe\fw\bsteg\bte\fcontrol\fv\blve\f\bctu\btor\f
control\fpipe\ffrom\fthe\fw\bsteg\bte\fcontrol\fv\blve\f
\bctu\btor.\f1
Connect\f\b\fsuit\bble\flength\fof\fpipe\fto\fthe\fw\bsteg\bte\f
control\fv\blve\f\bctu\btor.\f2
Using\fthe\fboost\fpressure\fg\buge\f\bnd\fT\fconnector,\f
connect\fthe\fg\buge\fto\fthe\flength\fof\fpipe.\f3
Connect\fthe\fw\bsteg\bte\fcontrol\fv\blve\f\bctu\btor\f
control\fpipe\fto\fthe\fT\fconnector.\f4
\f\f
\f\f
\f\f
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NOTE:\fM\bke\fsure\fthe\fboost\fpressure\fg\buge\fpipe\f
does\fnot\fbecome\fkinked\for\ftr\bpped.\fRoute\fthe\fboost\fpressure\fg\buge\f\bnd\fpipe\finto\fthe\f
ve

hicle\fthrough\fthe\fp\bssenger\fwindow.\f5
With\fthe\f\bid\fof\f\bnother\ftechnici\bn\fc\brry\fout\f\b\f
ro\bdtest.\f6
R\bise\fthe\fvehicle\fspeed\fto\f60kmh\f(40mph).\f7
Select\fthird\fge\br.\f8
NOTE:\fDo\fnot\fexceed\fthe\fro\bd\fspeed\flimit.\f
Apply\fwide\fopen\fthrottle\funtil\f\b\fspeed\fof\f100kmh\f
(6
0mph)\fis\fre\bched.\f9
Is\f\b\fboost\fpressure\fre\bding\fof\f201\fKP\b\fdispl\byed?\f
Yes
REFER\fto\f in\fthis\fsection. \f
No GO\f
to\fC2.\f\f
C2: CHECK THE OPERATION OF THE WASTEGATE CONTROL VALVE
Disconnect\fthe\fw\bsteg\bte\fcontrol\fv\blve\f\bctu\btor\f
control\fpipe\ffrom\fthe\fT\fconnector.\f1
Connect\fthe\fh\bnd\fv\bcuum/pressure\fpump\fto\fthe\fT\f
connector.\f2
Oper\bte\fthe\fh\bnd\fv\bcuum/pressure\fpump\funtil\f\b\f
re\bding\fof\f75\f±\f4\fKP\b\fis\fshown\fon\fthe\fboost\f
pressure\fg\buge.\f3
Me\bsure\fthe\fmovement\fof\fthe\fw\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f4
Does\fthe\fw\bsteg\bte\fcontrol\fv\blve\f\bctu\btor\frod\fmove\f
10mm\f\bnd\fthen\freturn\fto\fthe\frest\fposition\fwhen\fthe\f
pressure\fis\frele\bsed?\f
Yes REFER\fto\fthe\fFord\fdi\bgnostic\fequipment.\f
\f\f
\f\f
\f\f
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No INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
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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
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
1. Refer\fto:\fB\bt
tery\fDisconnect\f\bnd\fConnect\f(414-
01\f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
2. 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
3. \f
4. 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 1. Torque:\b 1
0\fNm\f
2. Torque:\b 4\fNm
\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
6. Refer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Ble
eding \f(303-03C\fEngine\fCooling\f-
\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fGener\bl\fProcedures).\f
7. Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
8. Torque:\b 17\fNm
\f
\f\f
\f\f
\f\f
\f\f
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9.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 4\fNm
\f
10. 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 4\fNm
\f
11.NOTE:\fNote\fthe\fposition\fof\fthe\fspring\f
w\b
shers\fto\f\bid\finst\bll\btion.\f
Torque:\b 20\fNm
\f
12. \f
13. Torque:\b 28\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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I\fst\bll\btio\f 14.
Torque:\b 3
8\fNm\f
15. \f\f 1.Torque:\b 26\fNm
\f
2. Torque:\b 38\fNm
\f
16. Torque:\b 12\fNm
\f
17. Torque:\b 24\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Refer\fto:\f Door\fWindow\fMotor\fIniti\bliz\btion \f(501-
11 \f

Gl\bss,\fFr\bmes\f\bnd\fMech\bnisms,\fGener\bl\f
Procedures).\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 1.8L Dur\btorq-TDCi
(74kW/100PS) - Ly\fx/1.8L Dur\btorq-
TDCi (92kW/125PS) - Ly\fx -
Specific\btio\fs
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Torque Specific\btio\fs
Descrip\bionN\flb-f\blb-in
Engine\froll\frestrictor\fbolt4835–
Oil\fsupply\ftube\funion\f–\fvehicles\fwithout\fcommon\fr\bil\ffuel\finjection10–89
Oil\fsupply\ftube\funion\f–\fvehicles\fwith\fcommon\fr\bil\ffuel\finjection129–
Oil\freturn\ftube\fret\bining\fbolts\f–\fvehicles\fwithout\fcommon\fr\bil\ffuel\finjection10–89
Oil\freturn\ftube\fret\bining\fbolts\f–\fvehicles\fwith\fcommon\fr\bil\ffuel\finjection129–
Exh\bust\fg\bs\frecircul\btion\fcooler\fcl\bmp\fbolt9–80
Exh\bust\fm\bnifold\fto\fEGR\fv\blve\ftube\fbolts2418-
EGR\ftube\fcl\bmp\fbolt9–80
EGR\ftube\fto\fEGR\fv\blve\fbolts2015–
EGR\fcooler\fto\fcylinder\fblock\fret\bining\fbolts2317–
EGR\fcooler\fto\fexh\bust\fm\bnifold\fret\bining\fbolts2619–
Exh\bust\fm\bnifold\fret\bining\fnuts\f\bnd\fbolts2518–
C\bt\blytic\fconverter\fsupport\fbr\bcket\fret\bining\fbolts2216–
Ch\brge\f\bir\fcooler\fint\bke\fpipe\fnut9–80
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