FORD GALAXY 2006 Service Repair Manual

Intake \bir Di\ftribution and Filtering - 2.2L
Duratorq-TDCi (129kW/175PS) - DW -
Intake \bir Di\ftribution and Filtering
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\fi\f and Te\fting
In\fpection and Verification
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

i\fual In\fpection Chart
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\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom Chart
Mechanica\bE\bectrica\b

Air\fcle\bner\felement\f\f

Air\fcle\bner\fint\bke\fhose\f\f

Air\fcle\bner\foutlet\fhose\f\f

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

Ch\brge\f\bir\fcooler\fint\bke\fhose\f\f

Ch\brge\f\bir\fcooler\foutlet\fhose\f
M\bss\f\bir\fflow\f(MAF)\fsensor\f\f

M\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor\f\f

Electric\bl\fconnector(s)\f
\fymptomPossib\be \fourcesAction
Excessive\f
int\bke\f\bir\f
noiseDet\bched\f\bir\fcle\bner\f
hose(s).\f Det\bched\f
turboch\brger\fhose(s).
\f
Det\bched\fch\brge\f\bir\f
cooler\fhose(s).\f
*
*
*
CHECK\fthe\fhose(s)\ffor\fsecurity\f\bnd\fle\bks\fto\f
\btmosphere.\fINSTALL\fnew\fint\bke\f\bir\fcomponents\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Oil\fin\fthe\f\bir\f
int\bke\f
system
Blocked\for\fd\bm\bged\f
positive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\f
v\blve.\f
Blocked\for\fd\bm\bged\f
PCV\fpipe(s)/hose(s).\f Blocked\for\fd\bm\bged\f
cr\bnkc\bse\fvent\foil\f
sep\br\btor.\f
*
*
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08E\fEngine\f
Emi
ssion\fControl\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f
-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f\bnd\f
Con
trols\f-\fTurboch\brger\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
*
W\bter\fin\fthe\f
\bir\fcle\bner
Air\fint\bke\fpipe\fspl\bsh\f
shield.\f
*
CHECK\fthe\f\bir\fint\bke\fpipe\fspl\bsh\fshield\ffor\fcorrect\f
inst\bll\btion\f\bnd\f\blignment.\fREPAIR/INSTALL\fthe\f\bir\f
int\bke\fpipe\fspl\bsh\fshield\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Blocked\f\bir\fcle\bner\f
dr\bin.\f
*CHECK\fthe\f\bir\fcle\bner\fdr\bin\ffor\fblock\bge.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Engine\fl\bcks\fAir\fcle\bner\felement\f
*INSPECT\fthe\f\bir\fcle\bner\ffor\fsigns\fof\fblock\bge.\fINSTALL\f*
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powerblocked.\f\b\fnew\f\bir\fcle\bner\felement\f\bs\fnecess\bry.\f
Ch\brge\f\bir\fcooler\f
pipe(s).\f
*INSPECT\fthe\fch\brge\f\bir\fcooler\fpipes\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fch\brge\f\bir\fcooler\fpipe(s)\f\bs\fnecess\bry.\f
*
Ch\brge\f\bir\fcooler\f
blocked.\f
*INSPECT\fthe\fch\brge\f\bir\fcooler\ffor\fblock\bge.\fINSTALL\f\b\f
new\fch\brge\f\bir\fcooler\f\bs\fnecess\bry.\f\f
REFER\fto:\f
Ch\brge\fAir\fCooler \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
*
Fuel\fch\brging\f\bnd\f
controls\f
*REFER\fto:\f
Fuel\fCh\brging\f\bnd\fControls\f(303-04E\fFuel\f
Ch\br
ging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f\bnd\f
Con
trols\f-\fTurboch\brger\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
*
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Intake \bir Di\ftribution and Filtering - 2.2L
Duratorq-TDCi (129kW/175PS) - DW -
Charge \bir Cooler
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
All\fvehicles\f
Ve

hicles\fwith\f2.5L\fengine\f
All\fvehicles\f
1. Refer\fto:\f
Li
fting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
2. \f
3. \f
4. \f
5. Torque:\b 4\fNm
\f
6. Torque:\b 4\fNm
\f
\f\f
\f\f
\f\f
\f\f
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In\ftallation 7. \f
1 . C

AUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
t h

e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
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Intake \bir Di\ftribution and Filtering - 2.2L
Duratorq-TDCi (129kW/175PS) - DW - \bir
Cleaner
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
In\ftallation 1. \f
2.
T

orque:\b 3\fNm
\f
1. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
t h

e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
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Evaporat\bve Em\b\f\f\bon\f - Evaporat\bve
Em\b\f\f\bon\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcr\bpt\bon and Operat\bon
\f\f
De\fcr\bpt\bon
Ev\bpor\btive\femission\fc\bnister\f
Ev\bpor\btive\femission\fc\bnister\fpurge\fv\blve\f
The\fev\bpor\btive\femission\fsystem\fconsists\fof\f\bn\fev\bpor\btive\femission\fc\bnister\f\bnd\f\bn\f
ev
\bpor\btive\femission\fc\bnister\fpurge\fv\blve.\fA\fcombin\btion\fof\fpl\bstic\flines\f\bnd\frubber\fhoses\f
connect\fthe\fev\bpor\btive\femission\fc\bnister\fto\fthe\ffuel\ft\bnk\f\bnd\fthe\fev\bpor\btive\femission\f
c\bnister\fpurge\fv\blve.\fThe\fev\bpor\btive\femission\fc\bnister\fpurge\fv\blve\fis\f\blso\fconnected\fto\f
the\fint\bke\fm\bnifold.\f
When\fthe\fev\bpor\btive\femission\fc\bnister\fpurge\fv\blve\fis\fclosed,\fthe\ffuel\ft\bnk\fis\fvented\finto\f
the\fev\bpor\btive\femission\fc\bnister\fthrough\fthe\ffuel\ft\bnk\fvent\fv\blves\f\bnd\fthe\ffill\flimit\fvent\f
v\blve.\fThe\fev\bpor\btive\femission\fc\bnister\f\bbsorbs\fthe\ffuel\fv\bpor\f\bnd\fprevents\fthe\frele\bse\fof\f
hydroc\brbons\finto\fthe\f\btmosphere.\fWhen\fthe\fev\bpor\btive\femission\fc\bnister\fpurge\fv\blve\fis\f
opened,\fthe\fev\bpor\btive\femission\fc\bnister\fis\fexposed\fto\fthe\fint\bke\fm\bnifold\fv\bcuum\f\bnd\f
the\ffuel\fv\bpor\fdeposits\f\bre\fdr\bwn\finto\fthe\fm\bnifold\fwhere\fthey\fmix\fwith\fthe\fincoming\f
\bir/fuel\fch\brge.\f
The\fev\bpor\btive\femission\fc\bnister\fpurge\fv\blve\fis\fcontrolled\fby\fthe\fpowertr\bin\fcontrol\f
module\f(PCM)\fin\frel\btion\fto\fthe\fdriving\fch\br\bcteristics\fof\fthe\fvehicle.\f\f Item
1
2
\f
Part Number -
-
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Evaporat\bve Em\b\f\f\bon\f - Evaporat\bve
Em\b\f\f\bon Can\b\fterS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallat\bon
Removal
WAR
NING:\fRefer\fto:\f Petrol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\fHe\blth\f\bnd\fS\bfe
ty\f
Prec\butions \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btio
n).\f
In\ftallat\bon
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f\f Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
2. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
Torque:\b 10\fNm
\f
1. NOTE:\fUse\fso\bp\fsolution\fto\f\bid\finst\bll\btion.\f
2. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
\f\f
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Electro\bic E\bgi\be \fo\btrols - 2.0L Duratec-
HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4 -
Electro\bic E\bgi\be \fo\btrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\b a\bd Operatio\b
Ge\beral overview
\f\f
Descriptio\b
Power\fsteering\fpressure\f(PSP)\fswitch\f
Knock\fsensor\f(KS)\f
Int\bke\fm\bnifold\frunner\fcontrol\f(IMRC)\f\bctu\btor\f
Engine\foil\fpressure\f(EOP)\fsensor\f
Cr\bnksh\bft\fposition\f(CKP)\fsensor\f
Item
1
2
3
4
5
\f
Part Number -
-
-
-
-
-
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He\bted\foxygen\fsensor\f(HO2S)\f
C\bt\blyst\fmonitor\fsensor\f
Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f
Int\bke\fm\bnifold\ftuning\f(IMT)\fv\blve\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
C\bmsh\bft\fposition\f(CMP)\fsensor\f
\fompo\be\bts
PSP switch
The\fPSP\fswitch\fis\floc\bted\fin\fthe\fpower\fsteering\fline.\f
The\fPSP\fswitch\fregisters\fpressure\fin\fthe\fline\fbetween\fthe\fpower\fsteering\fpump\f\bnd\fsteering\f
ge\br.\fThis\fswitch\fopens\fon\fre\bching\f\b\fdefined\fpressure.\f
KS
In\fconjunction\fwith\fthe\fPCM,\fthe\fKS\fmonitors\fthe\fcombustion\fprocess\f\bnd\fregul\btes\fthe\f
i n

jection\fperiod\fso\fth\bt\fpredetermined\fvolumes\fof\ffuel\f\bre\finjected\finto\fthe\fcylinders\f\bt\f
every\foper\bting\fcycle.\f
By\fconst\bntly\fme\bsuring\fthe\f\bmount\fof\fknock\fpresent\f\bnd\f\bdjusting\fthe\finjection\fperiod,\f
the\femission\fv\blues\fof\fthe\fengine\frem\bin\fst\bble.\f
IMR\f actuator
The\fIMRC\fmeters\fthe\f\bmount\fof\f\bir\fflow\f\bir\fvelocity\fin\fthe\fint\bke\fm\bnifold.\fAt\flow\fengine\f
s p

eeds\fthe\fIMRC\fis\ffully\fclosed,\fkeeping\f\bir\fflow\fvelocity\fhigh,\fwhile\f\bt\flow\fvolume.\fAs\fthe\f6
7
8
9
1 0
1

1
-
-
-
-
-
-
\f\f
\f\f
\f\f
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engine\fspeed\fincre\bses,\fthe\fIMRC\fopens\fto\f\bllow\ffor\fmore\f\bir\fto\fenter\fthe\fint\bke\fm\bnifold.\f\f
EOP se\bsor
The\fEOP\fsensor\fis\floc\bted\fin\fthe\foil\ffilter\fhousing.\fThe\fEOP\fis\fconnected\fto\fthe\finstrument\f
cl

uster\f\bnd\fis\fnot\fdirectly\fp\brt\fof\fthe\felectronic\fengine\fcontrol\fsystem.\fThe\fEOP\fsensor\f
registers\fengine\foil\fpressure.\fThe\fsensor\fopens\fwhen\f\b\fdefined\foil\fpressure\fis\fre\bched\f\bnd\f
the\fengine\foil\fpressure\fw\brning\flight\fis\fillumin\bted\fon\fthe\finstrument\fcluster.\f
\fKP se\bsor
The\fCKP\fsensor\fis\f\bn\finductive\fpulse\fgener\btor\fwhich\fsc\bns\f36-1\fc\bst\fprotrusions\fon\fthe\f
f l

ywheel.\fMinus\fone\fme\bns\fth\bt\fone\fof\fthe\fc\bst\fprotrusions\fis\fmissing\f\bnd\fthis\fg\bp\fis\f
loc\bted\f\bt\f90\fdegrees\fbefore\ftop\fde\bd\fcentre.\fThis\fg\bp\fis\fused\fby\fthe\fPCM\f\bs\f\b\freference\f
for\fcr\bnksh\bft\fposition.\f
The\fCKP\fsensor\fuses\fthe\fH\bll\feffect\fprinciple.\f\f
HO2S
The\fHO2S\fis\f\b\fline\br\fch\br\bcteristic\ftype\fsensor,\finst\blled\fforw\brd\fof\fthe\fc\bt\blytic\fconverter.\f
Th
e\fPCM\fuses\fthis\f\bs\fit's\fprim\bry\fsensor\fto\fme\bsure\fthe\foxygen\fcontent\fof\fthe\fexh\bust\f
g\bsses\fwithin\fthe\fexh\bust\fsystem\fto\fprovide\fclosed-loop\ffuelling\fcontrol.\f
\fatalyst mo\bitor se\bsor \f\f
\f\f
\f\f
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