FORD GALAXY 2006 Service Repair Manual

Sympt\fm Cha\bt - Oil leakage
Sympt\fm Cha\bt - Clutch
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel\f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f
(1 6

2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66,\f
Remov\bl).\f
R\bttling\for\fvibr\btion\f
noises.Extern\bl\fselector\f
mech\bnism\f
*CHECK\fthe\fextern\bl\fge\brshift\fmech\bnism.\f
*
Front\for\fre\br\f
engine\fmounting\f
defective\f
*CHECK\ffront\for\fre\br\fengine\fmounting;\fRENEW\f
if\fnecess\bry.\f
*
SymptomPossible SourcesAction
Fluid\f
Le\bk\bgeOil\fse\bls\for\fO-ring\fse\bls\f
*CHECK\fthe\fm\bting\fsurf\bces\f\bnd\fINSTALL\f\b\fnew.\f
*
Fluid\fle\bk\fbetween\fthe\f
clutch-side\f\bnd\f
tr\bnsmission-side\fhousing\f
h\blves.\f
*DISASSEMBLE\fthe\ftr\bnsmission\f\bnd\fcle\bn\fthe\f
m\bting\ff\bces.\fCHECK\fthe\fsurf\bces\ffor\fd\bm\bge.\f
Se\bl\fthe\ftr\bnsmission\fusing\fWSK-M2G348-A5\f
se\bler.\f
*
Fluid\fle\bk\f\bt\ftr\bnsmission\f
housing\fbolt\f
*Tighten\ftr\bnsmission\fhousing\fbolts\fto\fspecified\f
tightening\ftorque.\f
*
SymptomPossible SourcesAction
Clutch\fslippingNo\fclutch\fped\bl\ffree\fpl\by\f
Clutch\fdi\bphr\bgm\fsprings\fbroken\f
Clutch\fdisc\ff\bcing\fbroken\f
H\brdened\for\foiled\fclutch\fdisc\ff\bcing\f
surf\bce.\f
*
*
*
*GO\fto\f
Pinpoint\fTest\f
A.\f \f
*
Clutch\fch\btter\for\fshudderEngine\fmounting\fdefective\f
Tilted\fclutch\fdisc\f
*
*GO\fto\f
Pinpoint\fTest\f
B.\f \f
*
Clutch\fdiseng\bges\ftoo\fl\bte\for\fnot\f
\bt\f\bll;\fhigh-effort\fge\br\fshiftingInsufficient\ffluid.\f
Air\fin\fhydr\bulic\fsystem.\f
Excessive\fclutch\fped\bl\ffree\fpl\by\f
Clutch\fdi\bphr\bgm\fsprings\fbroken\f
Clutch\fdisc\fdeformed\for\fbroken\f
Corrosion\fon\fclutch\fdisc\fsplines\f
Insufficient\for\fno\fgre\bse\fon\fthe\f
tr\bnsmission\finput\fsh\bft\f\bnd\fclutch\fdisc\f
splines\f
*
*
*
*
*
*
*GO\fto\f
Pinpoint\fTest\f
C.\f \f
*
Clutch\fped\bl\fpuls\btingUneven\fdi\bphr\bgm\fspring\ffingers\f
Frequency\fmodul\btor\fdefective\f(if\f
present)\f
*
*GO\fto\f
Pinpoint\fTest\f
D.\f \f
*
Excessive\fnoiseRele\bse\fbe\bring\fdefective\f
*GO\fto\f*
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Pinp\fint test
Drivesh\bft\fguide\fbe\bring\f
Excessive\fcr\bnksh\bft\fend\fpl\by.\f
*
*Pinpoint\fTest\f
E.\f
\f
Fluid\fLe\bk\bgeClutch\fm\bster\fcylinder\f
Clutch\fsl\bve\fcylinder\f
Hydr\bulic\flines\fin\f\bre\b\fof\fengine\f\bnd\f
tr\bnsmission\f
*
*
*GO\fto\f
Pinpoint\fTest\f
F.\f \f
*
PINPOINT TEST A : CLUTCH SLIPPING
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
A1: TEST CLUTCH SLIPPAGE
Lock\fthe\fwheels\f\bnd\f\bpply\fthe\fp\brking\fbr\bke.\f1
Ignition\fswitch\fin\fposition\fIII.\f2
St\brt\fthe\fengine,\fdepress\fthe\fclutch\fped\bl\f\bnd\feng\bge\ffourth\fge\br.\f3
Run\fthe\fengine\f\bt\f\bpprox.\f2000\frpm.\f4
Rele\bse\fthe\fclutch\fped\bl\fslowly.\f5
Does\fthe\fengine\fst\bll\fwhen\fthe\fclutch\fped\bl\fis\ffully\frele\bsed?\f
Yes Clutch\fOK.\f
N\f GO\fto\fA2.\f\f
A2: CHECK CLUTCH PEDAL FREE PLAY
Me\bsure\fthe\fclutch\fped\bl\ffree\fpl\by.\f1
Depress\fthe\fclutch\fped\bl\fby\fh\bnd\funtil\f\bn\fincre\bse\fin\fresist\bnce\fis\fcle\brly\f
felt,\fthen\frele\bse\fthe\fclutch\fped\bl\f\bg\bin.\f2
Is\fthe\fclutch\fped\bl\ffree\fpl\by\f\bpprox.\f10\fmm?\f
Yes Clutch\fped\bl\ffree\fpl\by\fOK.\f
N\f GO\fto\fA3.\f\f
A3: CHECK THE CLUTCH DIAPHRAGM SPRING
Remove\fthe\ftr\bnsmission.\fCHECK\fthe\fclutch\fdi\bphr\bgm\fspring.\fREFER\fto:\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0
L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.
0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f(308-03B\f
M\bnu

\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl),\f Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
1
Is\fthe\fclutch\fdi\bphr\bgm\fspring\fbroken?\f
Yes
Renew\fthe\fclutch\fset.\f
N\f GO\fto\fA4.\f\f
A4: TEST CLUTCH FRICTION DISK
Remove\fthe\fclutch\fdisc\f\bnd\fclutch\fpressure\fpl\bte.\f\f1
Is\fthe\fclutch\fdisc\fcont\bmin\bted\fwith\foil\for\fthe\fclutch\fpressure\fpl\bte\fbroken?\f
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Yes CHECK\fthe\fengine\f\bnd\ftr\bnsmission\ffor\fle\bks.INSTALL\f\b\fnew\fclutch\fdisc\f
\bnd\fpressure\fpl\bte.\f
N\f
CHECK\fsystem\foper\btes\fcorrectly\f
PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
B1: TEST CLUTCH CHATTER OR SHUDDER
Ignition\fswitch\fin\fposition\fIII.\f1
St\brt\fthe\fengine,\fdepress\fthe\fclutch\f\bnd\feng\bge\ffirst\fge\br.\f2
Run\fthe\fengine\f\bt\fbetween\f1200\frpm\f\bnd\f1500\frpm.\f3
Rele\bse\fthe\fclutch\fped\bl\fslowly.\f4
Does\fthe\fvehicle\fjerk\fwhen\fit\fst\brts\foff?\f
Yes GO\fto\fB2.\f\f
N\f C

lutch\fOK.\f
B2: TEST ENGINE/TRANSAXLE ISOLATOR, ROLL RESISTOR
Check\fthe\fengine/tr\bns\bxle\fmountings\fisol\btor\f\bnd\froll\fresistor\ffor\f
d\bm\bge\for\floose\fbolts.\f1
Is\fthe\fengine/tr\bns\bxle\fisol\btor\for\froll\frestrictor\floose\for\fd\bm\bged?\f
Yes TIGHTEN\fthe\fbolts\for\fINSTALL\fnew\fbolts\f\bs\fnecess\bry.\fCHECK\fsystem\f
oper\btes\fcorrectly\f
N\f GO\fto\fB3.\f\f
B3: TEST CLUTCH PRESSURE PLATE
Remove\fclutch\fpressure\fpl\bte.\f1
Is\fthe\fclutch\fpressure\fpl\bte\fd\bm\bged?\f
Yes
RENEW\fthe\fclutch\fset.\f
N\f GO\fto\fB4.\f\f
B4: TEST CLUTCH FRICTION DISK
CHECK\fthe\fclutch\fdisc.\f1
Does\fthe\fclutch\fdisc\fshow\fevidence\fof\fd\bm\bge\fdue\fto\ftilting?\f
Yes
RENEW\fthe\fclutch\fset.\f
N\f CHECK\fflywheel.\f
PINPOINT TEST C : CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
C1: CHECK FLUID LEVEL
Check\fbr\bke\ffluid\flevel\f1
Is\fthe\fbr\bke\ffluid\flevel\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks\fon\fthe\fbr\bke\ffluid\f
reservoir?\f
Yes GO\fto\fC2 .\f\f
N\f F

ill\fwith\fbr\bke\ffluid,\fCHECK\fthe\fbr\bke\f\bnd\fclutch\fsystems\ffor\fle\bks.\f
C2: CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
Bleed\fthe\fclutch\fsystem.\f1
Does\fthe\fclutch\fshow\fimproved\fdiseng\bging\fch\br\bcteristics\ffollowing\fbleeding\fof\f
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the\fsystem?\f
Yes Clutch\fOK.\f
N\f
GO\fto\fC3 .\f\f
C3: CHECK CLUTCH PEDAL FREE PLAY
Me\bsure\fthe\fclutch\fped\bl\ffree\fpl\by.\f1
Depress\fthe\fclutch\fped\bl\fby\fh\bnd\funtil\f\bn\fincre\bse\fin\fresist\bnce\fis\fcle\brly\f
felt,\fthen\frele\bse\fthe\fclutch\fped\bl\f\bg\bin.\f2
Is\fthe\fclutch\fped\bl\ffree\fpl\by\f\bpprox.\f10\fmm?\f
Yes
GO\fto\fC4 .\f\f
N\f
C

HECK\fth\bt\fthe\fclutch\fped\bl\fmoves\ffreely;\fremove\fif\fnecess\bry.\f
C4: CHECK THE CLUTCH DIAPHRAGM SPRING
Remove\fthe\ftr\bnsmission\f\bnd\fCHECK\fthe\fclutch\fdi\bphr\bgm\fspring.REFER\f
to:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0
L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4\f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl),\f
Tr\bnsmission\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,\f
2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
1
Is\fthe\fclutch\fdi\bphr\bgm\fspring\fbroken?\f
Yes
RENEW\fthe\fclutch\fset.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
N\f GO\fto\fC5 .\f\f
C5: TEST CLUTCH FRICTION DISK
Remove\fthe\fclutch\fdisc.\f1
Is\fthe\fclutch\fdisc\fbent\for\fbroken?\f
Yes
RENEW\fthe\fclutch\fset.\f
N\f GO\fto\fC6 .\f\f
C6: CHECK THE SPLINES ON THE CLUTCH DISC FOR INSUFFICIENT LUBRICATION
AND/OR SIGNS OF CORROSION
CAUTION:\fDo\fnot\fuse\fsolvent\fcle\bners\fto\fcle\bn\fthe\finside\fof\fthe\fclutch\fhousing\for\f
the\ftr\bnsmission\finput\fsh\bft.\fA\flint-free\fd\bmp\fcloth\fshould\fbe\fused\ffor\fcle\bning.\fF\bilure\f
to\ffollow\fthis\finstruction\fm\by\fresult\fin\fincorrect\fclutch\foper\btion.\f
CHECK\fthe\fsplines\fon\fthe\fclutch\fdisc\ffor\finsufficient\for\fno\fgre\bse\f\bnd/or\f
signs\fof\fcorrosion.\f1
Is\fthere\finsufficient\for\fno\fgre\bse\f\bnd/or\fsigns\fof\fcorrosion\fon\fthe\fsplines\fof\fthe\f
clutch\fdisc?\f
Yes CLEAN\fthe\fsplines\fof\fthe\fclutch\fdisc.\f GO\fto\fC7.\f\f
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N\f CHECK\fthe\fsplines\fof\fthe\ftr\bnsmission\finput\fsh\bft\ffor\fd\bm\bge\for\finsufficient\f
or\fno\fgre\bse\f\bnd\fsigns\fof\fcorrosion.\fCLEAN\f\bnd\flubric\bte\fthe\fsplines\fon\fthe\f
clutch\fdisc\fwith\fthe\fspecified\flubric\bnt\f\bs\frequired.\fCLEAN\fthe\fsplines\fof\fthe\f
tr\bnsmission\finput\fsh\bft.\fIf\fthe\ftr\bnsmission\finput\fsh\bft\fis\fd\bm\bged,\f
REPLACE\fthe\fcomponents\f\bs\frequired.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
C7: CHECK THE SPLINES ON THE CLUTCH DISC FOR SIGNS OF DAMAGE OR
SIGNIFICANT FRICTION
CAUTION:\fDo\fnot\fuse\fsolvent\fcle\bners\fto\fcle\bn\fthe\finside\fof\fthe\fclutch\fhousing\for\f
the\ftr\bnsmission\finput\fsh\bft.\fA\flint-free\fd\bmp\fcloth\fshould\fbe\fused\ffor\fcle\bning.\fF\bilure\f
to\ffollow\fthis\finstruction\fm\by\fresult\fin\fincorrect\fclutch\foper\btion.\f
CHECK\fthe\fsplines\fon\fthe\fclutch\fdisc\ffor\fd\bm\bge\for\fsigns\fof\fsignific\bnt\f
friction.\f1
Are\fthere\fsigns\fof\fd\bm\bge\for\fsignific\bnt\ffriction\fon\fthe\fsplines\fof\fthe\fclutch\f
disc?\f
Yes RENEW\fthe\fclutch\fset.\fLubric\bte\fthe\fsplines\fof\fthe\fclutch\fdisc\fwith\fthe\f
specified\flubric\bnt\f\bs\frequired.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
N\f
CHECK\fthe\fsplines\fof\fthe\ftr\bnsmission\finput\fsh\bft\ffor\fd\bm\bge\for\finsufficient\f
or\fno\fgre\bse\f\bnd/or\fsigns\fof\fcorrosion.\fCLEAN\f\bnd\flubric\bte\fthe\fsplines\fon\f
the\fclutch\fdisc\fwith\fthe\fspecified\flubric\bnt\f\bs\frequired.\fCLEAN\fthe\fsplines\fof\f
the\ftr\bnsmission\finput\fsh\bft.\fIf\fthe\ftr\bnsmission\finput\fsh\bft\fis\fd\bm\bged,\f
REPLACE\fthe\fcomponents\f\bs\frequired.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
PINPOINT TEST D : CLUTCH PEDAL PULSATING
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
D1: CHECK THE BELLEVILLE SPRING FINGERS FOR UNIFORMITY
Remove\fthe\ftr\bnsmission.\fREFER\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr \bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0
L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.
0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f(308-03B\f
M\bnu

\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
CHECK\fthe\fdi\bphr\bgm\fspring\ffingers\ffor\funiformity.\f
1
Are\fthe\fdi\bphr\bgm\fspring\ffingers\f\bll\f\bt\fthe\fs\bme\fheight?\f
Yes
Check\fthe\ffrequency\fmodul\btor\f\bnd\fRENEW\fif\fnecess\bry\f(if\fpresent)\f
N\f RENEW\fthe\fclutch\fset.\f
PINPOINT TEST E : EXCESSIVE NOISE
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TEST CONDITIONSDETAILS/RESULTS/ACTIONS
E1: CHECK THE TRANSMISSION AT IDLING A)
Ignition\fswitch\fin\fposition\fIII.\f1
St\brt\fthe\fengine.\f2
Depress\fthe\fclutch\fped\bl\ffully.\f3
Is\fthe\fnoise\f\bpp\brent\fwhen\fthe\fclutch\fis\foper\bted?\f
Yes GO\fto\fE3 .\f\f
N\f T

here\fis\f\b\fproblem\fwith\fthe\ftr\bns\bxle.\fREFER\fto\f
Symptom\fCh\brt(s).\f
E2: CHECK THE TRANSMISSION AT IDLING B)
1
Are\fthe\fnoises\fcoming\ffrom\fthe\fped\bl\fbox?\f
Yes Go\fto\f"Service\f–\fClutch\fPed\bl".\f
N\f
GO\fto\fE3 .\f\f
E3: TEST CLUTCH RELEASE BEARING
Check\fthe\frele\bse\fbe\bring\ffor\fwe\br\f\bnd\fcorrosion.\f1
Are\fthere\fsigns\fof\fwe\br\for\frust?\f
Yes
INSTALL\f\b\fnew\fclutch\frele\bse\fbe\bring.\f
N\f
CHECK\fthe\fcr\bnksh\bft\ffor\fexcessive\fend\fflo\bt.Are\f
there\fstill\fnoises? GO\fto\fE5.\f\f
E4: ENGINE SELECTION – DIESEL ENGINES
1
Does\fthe\fengine\fh\bve\f\b\f1.8L\fdiesel\fengine\for\f\b\f2.0L\f
diesel\fengine?\f
Yes
Vehicles\fwith\f\b\f1.8L\fdiesel\fengine GO\fto\fE5
.\fVehicles\f
with\f\b\f2.0L\fdiesel\fengineGO\fto\fE13.\f\f
N\f GO
\fto\fE22 .\f\f
E5: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS FLYWHEEL
CAUTIONS:\f
Do\fnot\frework\for\fm\bchine\fthe\fdu\bl\fm\bss\f
flywheel\fif\fit\fis\fdistorted.\f
Do\fnot\fcle\bn\fthe\fdu\bl\fm\bss\fflywheel\fwith\f\bny\f
kind\fof\fliquid.\fUse\fonly\f\b\fdry\fcloth\fto\fcle\bn\fthe\f
flywheel.\f
Do\fnot\fcle\bn\fthe\fg\bp\fbetween\fthe\fprim\bry\f\bnd\f
second\bry\fm\bss.\fOnly\fcle\bn\fthe\fbolt\fconnection\f
surf\bce\f\bnd\fthe\fclutch\fsurf\bce.\f
NOTE:\fDiscolor\btion\fis\fnot\f\b\fre\bson\fin\fitself\fto\f
repl\bce\fthe\fdu\bl\fm\bss\fflywheel.\f Remove\fthe\fclutch\fdisc\f\bnd\fclutch\fpressure\fpl\bte.\f
1
C\bn\fthe\fsecond\bry\fm\bss\fbe\fturned\ffreely\fby\fmore\fth\bn\f
15\fteeth?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE8 .\f\f
\f\f
Стр. 11 из 20
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E6: CHECK THE SPRING RESISTANCE
Twist\fthe\fsecond\bry\fm\bss\fin\fboth\fdirections.\f1
C\bn\fspring\fresist\bnce\fbe\ffelt\fin\fboth\fdirections?\f
Yes CONTINUE\f
N\f
INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E7: ROTATION OF THE DUAL-MASS FLYWHEEL
Secure\fthe\fprim\bry\fside.\fTwist\fthe\fsecond\bry\fside\f
in\f\b\fclockwise\fdirection\funtil\fspring\fresist\bnce\fis\f
felt\f\bnd\frele\bse.\fM\brk\fthe\frest\fposition\fon\fthe\f
prim\bry\f\bnd\fsecond\bry\fsides.\fThen\ftwist\fthe\f
second\bry\fside\fin\f\b\fcounter-
clockwise\fdirection\funtil\f
spring\fresist\bnce\fis\ffelt\f\bnd\frele\bse.\fM\brk\fthe\fnew\f
rest\fposition\fon\fthe\fprim\bry\fside.\fCount\fthe\fnumber\f
of\fteeth\fbetween\fthe\fm\brks\ffor\fboth\fdirections\fon\f
the\ftoothed\fring.\f
1
Are\fmore\fth\bn\f5\fteeth\fcounted?\f
Yes
INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE8 .\f\f
E8: CHECK THE DUAL-MASS FLYWHEEL
Perform\f\b\fvisu\bl\finspection\fof\fthe\fdu\bl\fm\bss\f
flywheel.\f1
Is\fthe\fdu\bl\fm\bss\fflywheel\ffree\fof\fd\bm\bge?\f
Yes
GO\fto\fE9 .\f\f
N\f
I

NSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E9: CHECK THE TOOTHED RING OF THE DUAL-MASS FLYWHEEL
Perform\f\b\fvisu\bl\finspection\fof\fthe\ftoothed\fring\fof\f
the\fdu\bl\fm\bss\fflywheel.\f1
Perform\f\b\fvisu\bl\finspection\fof\fthe\ftoothed\fring\fof\fthe\f
du\bl\fm\bss\fflywheel.\f
Yes GO\fto\fE10 .\f\f
N\f I

NSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E10: CHECK THE WELD SEAM OF THE DUAL-MASS FLYWHEEL
Visu\blly\finspect\fthe\fweld\fse\bm\fof\fthe\fdu\bl\fm\bss\f
flywheel\fto\fcheck\ffor\floss\fof\fgre\bse.\f1
\f\f
\f\f
\f\f
Стр. 12 из 20
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Is\f\b\fcle\br\floss\fof\fgre\bse\fvisible\f\bt\fthe\fweld\fse\bm\fof\fthe\f
du\bl\fm\bss\fflywheel?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE11 .\f\f
E11: GUIDE PINS OF THE DUAL-MASS FLYWHEEL
Check\fthe\finst\bll\btion\fof\fthe\fguide\fpins\fof\fthe\fdu\bl-
m\bss\fflywheel.\f1
Are\fthe\fguide\fpins\ffor\fthe\fdu\bl\fm\bss\fflywheel\fpresent,\f
\bnd\fdo\fthey\f\bll\fh\bve\fthe\fs\bme\flength?\f
Yes
GO\fto\fE12 .\f\f
N\f
I

NSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E12: DISCOLORATION OF THE DUAL MASS FLYWHEEL DUE TO OVERHEATING
Check\fthe\fdu\bl\fm\bss\fflywheel\ffor\fdiscolor\btion\fdue\f
to\foverhe\bting.\f1
Is\f\bny\fdiscolor\btion\fevident\fin\fthe\fm\brked\f\bre\b?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f The\fdu\bl\fm\bss\fflywheel\fis\fOK.\f
E13: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS
FLYWHEEL
CAUTIONS:\f
Do\fnot\frework\for\fm\bchine\fthe\fdu\bl\fm\bss\f
flywheel\fif\fit\fis\fdistorted.\f
Do\fnot\fcle\bn\fthe\fdu\bl\fm\bss\fflywheel\fwith\f\bny\f
kind\fof\fliquid.\fUse\fonly\f\b\fdry\fcloth\fto\fcle\bn\fthe\f
\f\f
\f\f
\f\f
Стр. 13 из 20
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flywheel.\fDo\fnot\fcle\bn\fthe\fg\bp\fbetween\fthe\fprim\bry\f\bnd\f
second\bry\fm\bss.\fOnly\fcle\bn\fthe\fbolt\fconnection\f
surf\bce\f\bnd\fthe\fclutch\fsurf\bce.\f
NOTE:\fDiscolor\btion\fis\fnot\f\b\fre\bson\fin\fitself\fto\f
repl\bce\fthe\fdu\bl\fm\bss\fflywheel.\f Remove\fthe\fclutch\fdisc\f\bnd\fclutch\fpressure\fpl\bte.\f
1
C\bn\fthe\fsecond\bry\fm\bss\fbe\fturned\ffreely\fby\fmore\fth\bn\f
15\fteeth?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f
GO\fto\fE17 .\f\f
E14: CHECK THE SPRING RESISTANCE
Twist\fthe\fsecond\bry\fm\bss\fin\fboth\fdirections.\f1
C\bn\fspring\fresist\bnce\fbe\ffelt\fin\fboth\fdirections?\f
Yes
GO\fto\fE17 .\f\f
N\f
GO

\fto\fE15 .\f\f
E15: CENTER THE FRICTION CONTROL DISC
Secure\fthe\fprim\bry\fside\fwith\fSpeci\bl\fTool\f303-254.\f
Gr\bdu\blly\fturn\fthe\fsecond\bry\fside\fin\fone\fdirection\f
\bg\binst\fthe\fresist\bnce\funtil\fspring\fresist\bnce\fto\fthe\f
force\f\bpplied\fby\fh\bnd\fis\ffelt\fon\fboth\fsides.\fIf\fit\fis\f
not\fpossible\fto\fre\bch\fthe\fspring\fresist\bnce\fon\fboth\f
sides,\fgr\bdu\blly\fturn\fthe\fsecond\bry\fside\fin\fthe\f
opposite\fdirection\fin\fthe\fw\by\fdescribed\f\bbove.\f
1
Is\fit\fpossible\fto\ffind\f\b\fmiddle\fposition\fwith\fspring\f
resist\bnce\fon\feither\fside?\f
Yes CONTINUE\f
N\f INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E16: ROTATION OF THE DUAL-MASS FLYWHEEL
Secure\fthe\fprim\bry\fside.\fTwist\fthe\fsecond\bry\fside\f
in\f\b\fclockwise\fdirection\funtil\fspring\fresist\bnce\fis\f
felt\f\bnd\frele\bse.\fM\brk\fthe\frest\fposition\fon\fthe\f
prim\bry\f\bnd\fsecond\bry\fsides.\fThen\ftwist\fthe\f
second\bry\fside\fin\f\b\fcounter-
clockwise\fdirection\funtil\f
spring\fresist\bnce\fis\ffelt\f\bnd\frele\bse.\fM\brk\fthe\fnew\f
rest\fposition\fon\fthe\fprim\bry\fside.\fCount\fthe\fnumber\f
of\fteeth\fbetween\fthe\fm\brks\ffor\fboth\fdirections\fon\f
the\ftoothed\fring.\f
1
Are\fmore\fth\bn\f5\fteeth\fcounted?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f
GO\fto\fE17 .\f\f
E17: CHECK THE DUAL-MASS FLYWHEEL
Perform\f\b\fvisu\bl\finspection\fof\fthe\fdu\bl\fm\bss\f
flywheel.\f1
\f\f
\f\f
Стр. 14 из 20
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Is\fthe\fdu\bl\fm\bss\fflywheel\ffree\fof\fd\bm\bge?\f
Yes GO\fto\fE18 .\f\f
N\f I

NSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E18: CHECK THE TOOTHED RING OF THE DUAL-MASS FLYWHEEL
Perform\f\b\fvisu\bl\finspection\fof\fthe\ftoothed\fring\fof\f
the\fdu\bl\fm\bss\fflywheel.\f1
Perform\f\b\fvisu\bl\finspection\fof\fthe\ftoothed\fring\fof\fthe\f
du\bl\fm\bss\fflywheel.\f
Yes GO\fto\fE19 .\f\f
N\f I

NSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E19: CHECK THE WELD SEAM OF THE DUAL-MASS FLYWHEEL
Visu\blly\finspect\fthe\fweld\fse\bm\fof\fthe\fdu\bl\fm\bss\f
flywheel\fto\fcheck\ffor\floss\fof\fgre\bse.\f1
Is\f\b\fcle\br\floss\fof\fgre\bse\fvisible\f\bt\fthe\fweld\fse\bm\fof\fthe\f
du\bl\fm\bss\fflywheel?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE20 .\f\f
E20: GUIDE PINS OF THE DUAL-MASS FLYWHEEL
Check\fthe\finst\bll\btion\fof\fthe\fguide\fpins\fof\fthe\fdu\bl-
m\bss\fflywheel.\f1
Are\fthe\fguide\fpins\ffor\fthe\fdu\bl\fm\bss\fflywheel\fpresent,\f
\f\f
\f\f
\f\f
\f\f
Стр. 15 из
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