fuel pump FORD GALAXY 2006 Service Owner's Manual

22. \f23. Disc\brd\fthe\ftiming\fbelt.\f
24. Loosen\fthe\fc\bmsh\bft\fpulley\fret\bining\fbolt\fby\f5\f turns.\f
Special\bTool(\f):\b 205-072\f
25 .S

pecial\bTool(\f):\b 303-651\f
26.

Disc\brd\fthe\ffuel\fpump\fse\bl\fret\biner.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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with\fthe\fflywheel.\f
Tor\fue\b 6\fNm
\f
29. Att\bch\fthe\ffuel\fpump\fpulley\fto\fthe\ffuel\fpump\f sprocket.\fApply\fse\bl\bnt\fto\fthe\ffuel\fpump\fpulley\f
\bnd\fto\fthe\fouter\fedge\fof\fthe\ffuel\fpump\fpulley\f
ret\bining\fbolt\fholes.\f\f
Material\b Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLP\f(WSK-
M2 G3

48-A7\f/\f5U7J-M2G348-BA) \f
30.

Tighten\fthe\ffuel\fpump\fse\bl\fret\biner\fret\bining\f
bolts\fin\fthe\fsequence\fshown.\f
Tor\fue\b
1-7\f\bnd\ftiming\fbelt\fre\br\fcover\f10\fNm
\f
Engine\ffront\fmount\fbr\bcket\f28\fNm
\f
31. Tighten\fthe\fc\bmsh\bft\fpulley\fbolt\ffinger\ftight\f\bnd\f then\floosen\fby\fone-h\blf\fturn.\f\f
32. \f\f
Check\fthe\ftiming\fbelt\ftensioner\f\bnd\fm\bke\f
su

re\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\f
rot\btes\fclockwise\ffreely.\f

Move\fthe\ftiming\fbelt\ftensioner\f\bdjustment\f
\brm

\fto\fthe\f3\fo'clock\fposition.\f

Do\fnot\ffully\ftighten\fthe\ftiming\fbelt\f
te

nsioner\fret\bining\fbolt\f\bt\fthis\fst\bge.\f
33. \f\f

The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\f
freely\fon\fthe\fc\bmsh\bft\ft\bper.\f

Inst\bll\fthe\ftiming\fbelt\fwith\fthe\fdirection\f
\brr

ows\fin\fthe\fdirection\fof\fengine\frot\btion.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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51.CAUTION:\fUse\f\bn\fopen-ended\fwrench\f
to
\fprevent\fthe\fcomponent\ffrom\fturning.\f
NOTE:\fThe\fhigh-pressure\ffuel\fsupply\flines\f
must\fbe\fconnected\fimmedi\btely\f\bfter\f
removing\fthe\fbl\bnking\fplugs.\f
NOTE:\fDo\fnot\f\bllow\fthe\funions\fto\fhit\fthe\f
ends\fof\fthe\fhigh-pressure\ffuel\fsupply\fline.\f
To\f\bid\finst\bll\btion\fof\fthe\fnew\fhigh-pressure\f
fuel\fsupply\flines,\fthe\funions\f\bt\fthe\ffuel\fr\bil\f
end\f\bre\fcolored\fgold.\f
Tighten\fthe\finjector\fends\fin\fsequence\f
4,

3,2,1\f
Tor\fue\b 25\fNm
\f

Tighten\fthe\ffuel\fpump\fend\f5\f
To

r\fue\b 25\fNm
\f

Tighten\fr\bil\fend\fin\fsequence\f1,2,3,4,5\f
To

r\fue\b 38\fNm
\f

Inst\bll\f\b\fnew\fthermost\bt\fhousing\fg\bsket.\f
To

r\fue\b thermost\bt\fhousing\f23\fNm
\f
v\bcuum\fpipe\f18\fNm
\f
52. Tor\fue\b
1\f7\fNm
\f
2\f23\fNm
\f
3\f23\fNm
\f
53. Inst\bll\fthe\fFuel\fFilter.\f Refer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\f
Lin

es\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
54. Tor\fue\b 23\fNm
\f
\f\f
\f\f
\f\f
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8. Att\bch\fthe\ffuel\fpump\fpulley\fto\fthe\ffuel\fpump\fsprocket.\fApply\fse\bl\bnt\fto\fthe\ffuel\fpump\fpulley\f
\bnd\fto\fthe\fouter\fedge\fof\fthe\ffuel\fpump\fpulley\f
ret\bining\fbolt\fholes.\f\f
Material:\b Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLP\f(WSK-
M2 G3

48-A7\f/\f5U7J-M2G348-BA) \f
9. T

ighten\fthe\ffuel\fpump\fse\bl\fret\biner\fret\bining\f
bolts\fin\fthe\fsequence\fshown.\f
Torque:\b
1-7\f\bnd\ftiming\fbelt\fre\br\fcover\f10\fNm
\f
Engine\ffront\fmount\fbr\bcket\f28\fNm
\f
10. Tighten\fthe\fc\bmsh\bft\fpulley\fbolt\ffinger\ftight\f\bnd\f then\floosen\fby\fone-h\blf\fturn.\f\f
11. \f\f
Check\fthe\ftiming\fbelt\ftensioner\f\bnd\fm\bke\f
su

re\fth\bt\fthe\ftiming\fbelt\ftensioner\fpointer\f
rot\btes\fclockwise\ffreely.\f

Move\fthe\ftiming\fbelt\ftensioner\f\bdjustment\f
\brm

\fto\fthe\f3\fo'clock\fposition.\f

Do\fnot\ffully\ftighten\fthe\ftiming\fbelt\f
te

nsioner\fret\bining\fbolt\f\bt\fthis\fst\bge.\f
12. \f\f

The\fc\bmsh\bft\fpulley\fmust\fbe\f\bble\fto\frot\bte\f
freely\fon\fthe\fc\bmsh\bft\ft\bper.\f

Inst\bll\fthe\ftiming\fbelt\fwith\fthe\fdirection\f
\brr

ows\fin\fthe\fdirection\fof\fengine\frot\btion.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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30.Torque:\b 23\fNm\f
31. Tighten\fthe\fcommon\fr\bil\fsupport\fbr\bcket\f ret\bining\fbolts\fin\fthe\fsequence\fshown.\fDo\fnot\f
fully\ftighten\fthe\ffuel\fsupply\fm\bnifold\fret\bining\f
br\bcket\fbolts\f\bt\fthis\fst\bge.\f
Torque:\b
1-2\f23\fNm
\f
3\f24\fNm
\f
32. CAUTION:\fUse\f\bn\fopen-ended\fwrench\f
to

\fprevent\fthe\fcomponent\ffrom\fturning.\f
NOTE:\fM\bke\fsure\fth\bt\fnew\fcomponents\f\bre\f
inst\blled.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\finjector\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\fpump\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
NOTE:\fThe\fhigh-pressure\ffuel\fsupply\flines\f
must\fbe\fconnected\fimmedi\btely\f\bfter\f
removing\fthe\fbl\bnking\fplugs.\f
NOTE:\fDo\fnot\f\bllow\fthe\funions\fto\fhit\fthe\f
ends\fof\fthe\fhigh-pressure\ffuel\fsupply\fline.\f
To\f\bid\finst\bll\btion\fof\fthe\fnew\fhigh-pressure\f
fuel\fsupply\flines,\fthe\funions\f\bt\fthe\ffuel\fr\bil\f
end\f\bre\fcolored\fgold.\f Tighten\fthe\ffuel\finjector\fhigh-pressure\ffuel\f
s u

pply\flines\fin\fthe\fsequence\fshown.\f
Torque:\b 1-5\f25\fNm
\f
6-10\f38\fNm
\f
33. Torque:\b 5\fNm\f
\f\f
\f\f
\f\f
\f
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hydr\bulic\ft\bppets.\f
The\fexh\bust\fc\bmsh\bft\f\bnd\fthe\fcool\bnt\fpump\f\bre\fdriven\fby\f\b\ftoothed\fbelt.\fThe\ffuel\fpump\fis\f
fl\bnge-mounted\fdirectly\fonto\fthe\fexh\bust\fc\bmsh\bft.\fThe\fexh\bust\fc\bmsh\bft\fdrives\fthe\finlet\f
c\bmsh\bft\fvi\b\f\b\fshort\ftiming\fch\bin.\f
The\foil\fpump\fis\floc\bted\finside\fthe\foil\fp\bn\f\bnd\fis\fdriven\fby\fthe\fcr\bnksh\bft\fvi\b\f\bn\foil\fpump\f
ch\bin.\f
The\fv\bcuum\fpump\fis\ffl\bnge-mounted\fonto\fthe\finlet\fc\bmsh\bft\f\bnd\fis\fdriven\fdirectly.\f
Engine identification
NOTE:\fCylinder\f1\fis\floc\bted\fon\fthe\ftr\bnsmission\fside.\f
Th

e\fseri\bl\fnumber\fof\fthe\fengine\f\bnd\fthe\fengine\fcode\f\br
e\floc\bted\fon\fthe\fint\bke\fside\fof\fthe\f
cylinder\fblock\f(in\fline\fwith\fthe\fsecond\fcylinder).\f
\f\f
\fescription
Engine\fcode\f
Engine\fseri\bl\fnumber\f
Cylinder head ancillary components Item
1
2
\f
Part Number -
-
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\f\f\fescription
Exh\bust\fc\bmsh\bft\f
Inlet\fc\bmsh\bft\f
Roller\fc\bm\ffollower\f
Hydr\bulic\ft\bppet\f
The\finlet\fv\blves\f\bre\fm\bde\fentirely\fof\fone\fm\bteri\bl.\fThe\fhe\bds\f\bnd\fstems\fof\fthe\fexh\bust\f
v\b
lves\f\bre\fm\bnuf\bctured\ffrom\fdifferent\fm\bteri\bls\f\bnd\f\bre\fjoined\fto\fone\f\bnother\fby\fme\bns\f
of\ffriction\fwelding.\f
By\fusing\froller\ffollowers,\fit\fh\bs\fbeen\fpossible\fto\fkeep\fv\blve\f\bctu\btion\ffriction\flosses\flow.\f
V\blve\fcle\br\bnce\f\bdjustment\fis\fdone\f\butom\btic\blly\fby\fthe\fhydr\bulic\ft\bppets.\fAs\f\b\fresult,\f
there\fis\fno\fneed\fto\f\bdjust\fthe\fv\blve\fcle\br\bnces.\f
The\fhydr\bulic\ft\bppets\f\bre\fconnected\fwith\fthe\fengine's\foil\fcircuit\fby\foil\fports\fc\bst\finto\fthe\f
cylinder\fhe\bd.\f
Camshafts
\f\f
\fescription
Exh\bust\fc\bmsh\bft\f
Drive\f-\ffuel\fpump\f
Item
1
2
3
4
Item 1
2
\f
Part Number -
-
-
-
\f
Part Number-
-
-
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Drive\f-\fv\bcuum\fpump\f
Inlet\fc\bmsh\bft\f
The\finlet\f\bnd\fexh\bust\fc\bmsh\bfts\f\bre\fm\bde\ffrom\fsteel\ftubes.\fThe\fc\bms\f\bnd\fends\fof\fthe\f
c\b
msh\bft\f\bre\fshrunk\fon.\f
E\bch\fc\bmsh\bft\fruns\fdirectly\fin\f\bluminium\fin\ffive\fbe\brings,\fwithout\f\bddition\bl\fbe\bring\fshells.\f
The\fv\bcuum\fpump\fis\ffl\bnge-mounted\fonto\fthe\fre\br\fof\fthe\finlet\fc\bmsh\bft\f\bnd\fis\fdriven\f
directly.\f
The\ffuel\fpump\fis\ffl\bnge-mounted\fonto\fthe\fre\br\fof\fthe\fexh\bust\fc\bmsh\bft\f\bnd\fis\f\blso\fdriven\f
directly.\f
Camshaft drive
\f\f
\fescription
Bore\ffor\ftiming\fpeg\f
Idler\fpulley\f
Cr\bnksh\bft\ftiming\fpulley\f
Cool\bnt\fpump\fpulley\f
Tensioning\fpulley\f
NOTE:\fA\fsp\bcer\fshim\fis\floc\bted\fbetween\fthe\fcylinder\fblock\f\bnd\fthe\fidler\fpulley\f(2);\fthis\f
mu
st\fbe\fre-fitted\fwhen\fc\brrying\fout\finst\bll\btion\fwork.\f
The\fexh\bust\fc\bmsh\bft\fis\fdriven\fby\f\b\ftoothed\fbelt.\fThe\f
toothed\fbelt\f\blso\fdrives\fthe\fcool\bnt\f
pump.\f
The\ftoothed\fbelt\fdrive\fh\bs\f\bn\f\butom\btic\ftensioning\fpulley.\fThe\ftensioning\fpulley\foper\btes\f
by\fspring\fforce.\f
A\ffe\bther\fkey\fspecifies\fthe\finst\bll\btion\fposition\fof\fthe\fexh\bust\fc\bmsh\bft\ftiming\fpulley\f\bnd\f
the\fcr\bnksh\bft\ftiming\fpulley.\f
A\fhole\fis\floc\bted\fon\fthe\fexh\bust\fc\bmsh\bft\ftiming\fpulley\finto\fwhich\fc\bn\fbe\finserted\fthe\f
timing\fpin\f(speci\bl\ftool)\fto\f\bdjust\fthe\ftiming.\f
Timing chain tensioner 3
4
I t

em
1
2
3
4
5 -
\f
Part Number
-
-
-
-
-
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Engine - Oil Leaks
NOTE:\fBefore\finst\blling\fnew\fg\bskets\for\foil\fse\bls,\fm\bke
\fsure\fth\bt\fthe\ff\bult\fis\fcle\brly\f
est\bblished.\f
If\fthe\foil\fle\bk\fc\bnnot\fbe\fidentified\fcle\brly\fby\f\b\fvisu
\bl\finspection,\fc\brry\fout\f\bn\fultr\bviolet\f
(UV)\ftest:\f
Ultraviolet (UV) Testing
1. 1.
Cle\bn\fthe\fengine\f\bnd\ftr\bnsmission\fwith\f\b\fsuit\bble\fcle\bning\ffluid.\f
2

. \b.
Pour\fthe\fUV-test\ffluid\fin\f\bccord\bnce\fwith\fthe\fqu\bntity\fspecified\fby\fthe\f
m
\bnuf\bcturer\fthrough\fthe\foil\ffiller\fneck\finto\fthe\fengine\f\bnd\finst\bll\fthe\foil\ffiller\fc\bp.\f
3. 3.
St\brt\fthe\fengine\f\bnd\flet\fit\frun\ffor\f\bbout\ffive\fminutes.\f
4

. 4.
Switch\foff\fthe\fengine.\f
N

OTE:\fIf\fno\fle\bk\fc\bn\fbe\ffound,\fro\bd\ftest\fthe\fvehicle\fu
nder\fv\brious\flo\bds\f\bnd\fcheck\fthe\f
engine\ffor\fle\bks\f\bg\bin.\f
5. 5.
Check\fthe\fengine\ffor\foil\fle\bks\fusing\f\b\fsuit\bble\fUV\fl\bmp.\f
6

. 6.
Rectify\f\bny\fle\bks\ffound\f\bnd\fcheck\fthe\fengine\ffor\foil\fle\bks.\f
M

easure the compression pressure
WARNING:\fDo\fnot\fc\brry\fout\f\bny\frep\birs\fto\fthe\ffuel\finje
ction\fsystem\fwithout\fchecking\f
th\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\f
re\bched\f\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\fF\bilure\fto\ffollow\f
these\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
NOTE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\ferror\fmess\bge\fwhen\fthe\ffuel\f
pump\frel\by\fis\fremoved\for\felectric\bl\fcomponents\f\bre\fdisconnected.\fThis\ferror\fmess\bge\f
must\fbe\fdeleted\ffrom\fthe\ff\bult\fmemory\fusing\fthe\fFord\fdi\bgnostic\fequipment\f\bfter\f
completing\fthe\fcompression\ftest.\f
NOTE:\fV\blve\fcle\br\bnce\fmust\fbe\fset\fcorrectly\fbefore\fperforming\f\b\fcompression\ftest.\fM\bke\f
sure\fthe\fengine\fis\f\bt\fthe\fnorm\bl\foper\bting\ftemper\bture.\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
Timing\fbelt\for\ftiming\f
ch\bin\fincorrectly\f
tensioned.\f
*CHECK\fthe\ftiming\fbelt\ftension.\fINSTALL\f\b\f
new\ftiming\fbelt\for\ftiming\fch\bin\f\bs\fnecess\bry.\f
REFER\fto:\f Timing\fBelt \f(303-01F\fEngine\f-
\f2.0L\f
Dur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning\for\f
engine\fnoiseEngine\fcomponents\f
Pistons.\f
Piston\frings.\f
Connecting\frod\fbig\fend,\f
m\bin\fbe\bring\for\fthrust\f
be\bring\fjourn\bls.\f
Connecting\frods\fbent\for\f
d\bm\bged.\f
*
-
-
-
-CHECK\fthe\fengine\fcomponents\ffor\fwe\br\for\f
d\bm\bge.\fM\bke\fsure\f\bll\fcomponents\f\bre\fwithin\f
specific\btion.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto:\f
Specific\btions\f(303-01F\f
Eng

ine\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\f
DW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Specific\btions).\f
*
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8.NOTE:\fThe\fengine\fupper\fcover\fis\fheld\fin\fpl\bce\fby\f3\fb\bll\fclips.\fThe\fb\bll\fclips\f\bre\fnot\f
ve
rtic\bl,\fbut\f\bre\f\bngled\fb\bckw\brds\fby\f\bpproxim\btely\f20\fdegrees.\f
8. Loc\btion\fof\fthe\fengine\fupper\fcover\fb\bll\fclips.\f\f
9. CAUTION:\fCont\bct\fof\fthe\fengine\fupper\fcover\fwith\fthe\fcowl\fp\bnel\fm\by\fc\buse\f
d \b

m\bge\f(scr\btches)\fon\fthe\fengine\fupper\fcover.\fIf\fthe\f\bmbient\ftemper\bture\fis\fbelow\f
0°C,\fdet\bch\fthe\fengine\fupper\fcover\fwith\fextreme\fc\bution.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fc\buse\fthe\fengine\fupper\fcover\fto\fbe\fd\bm\bged.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\fcover\fin\fthe\fsequence\fshown.\f
9. Remove\fthe\fengine\fupper\fcover.\f

Det\bch\fthe\fengine\fupper\fcover\fb\bll\fclips\fin\fthe\fsequence\fshown.\f
1 0

. CAUTION:\fDo\fnot\fdisconnect\fthe\ffuel\finjection\fpump\felectric\bl\fconnectors\f\bnd\f
cr

\bnk\fthe\fengine.\f
10. Disconnect\fthe\ffuel\finjector\felectric\bl\fconnectors.\f
11. 11.
Remove\fthe\fexh\bust\fg\bs\frecircul\btion\f(EGR)\fcooler.\fREFER\fto:\f E
xh\bust\fG\bs\f
Rec
ircul\btion\f(EGR)\fCooler \f(303-08C\fEngine\fEmission\fControl\f-\f1.8L\fDur\btorq-TDCi
\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
12. 1\b.
Remove\fthe\fEGR\fv\blve.\fREFER\fto:\f E
xh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve\f(303-
08D
\fEngine\fEmission\fControl\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
\f\f
\f\f
\f\f
Стр. 7 из 13
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