engine FORD GALAXY 2006 Service Repair Manual

Filling and Bleeding
CAUTION:\fThe\ffluid\flevel\fmust\frem\bin\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks.\f 7. Inst\bll\fthe\fr\bdi\btor\fdr\bin\fplug.\f
8
.

Lower\fthe\fvehicle.\f
1. Switch\fthe\finterior\fhe\bter\fblower\foff.\f
2. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\fthe\ftop\fof\fthe\fneck.\f
3. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
4. St\brt\fthe\fengine.\f
5. R\bise\fthe\fengine\fspeed\fto\f2000\frevolutions\fper\f minute\f(RPM)\f\bnd\fm\bint\bin\fit\ffor\f3\fminute.\f
6. Monitor\fthe\fcool\bnt\flevel\ffor\f\bpproxim\btely\f3\f minutes.\f
7. Switch\fthe\fengine\foff.\f
8. Check\fthe\fcool\bnt\flevel.\f
9. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\f the\fneck\fof\fthe\ft\bnk\fif\fnecess\bry.\f
10. Inst\bll\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp.\f
11. St\brt\fthe\fengine.\f
12. R\bise\fthe\fengine\fspeed\fto\f2000\fRPM.\f
13. M\bint\bin\fthe\fengine\fspeed\f\bt\f2000\fRPM\ffor\f \bpproxim\btely\f13\fminutes\funtil\fthe\fengine\fh\bs\f
re\bched\fnorm\bl\foper\bting\ftemper\bture.\f
14. Incre\bse\fthe\fengine\fspeed\fto\f3000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f5\fseconds.\f
15. Decre\bse\fthe\fengine\fspeed\fto\f2000\fRPM\f\bnd\f m\bint\bin\fit\ffor\f15\fminutes.\f
16. Switch\fthe\fengine\foff.\f
17. Check\fthe\fcooling\fsystem\ffor\fle\bks.\f
18. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
19. \f
\f\f
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20. \f
21. Lower\fthe\fvehicle.\f
22. Allow\fthe\fengine\fto\fcool.\f
23. Fill\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fcool\bnt\flevel\fto\fthe\fMAX\fm\brk.\f
\f\f
\f\f
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Engine C\b\bling - 1\f8L Durat\brq-TDCi
(74kW/100PS) - Lynx/1\f8L Durat\brq-
TDCi (92kW/125PS) - Lynx - C\b\bling
System Draining and Vacuum Filling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Pr\bcedures
General Equipment
Draining
WARNING:\fWhen\frele\bsing\fthe\fcooling\fsystem\fpressure,\fcover\fthe\fcool\bnt\fexp\bnsion\f
t \b

nk\fc\bp\fwith\f\b\fthick\fcloth.\f
NOTE:\fAlw\bys\ffollow\fthe\fm\bnuf\bcturer's\finstructions\fwhen\fh\bndling\fthe\fequipment.\f
Cooling\fsystem\fv\bcuum\ftester\f\bnd\frefiller
Fluid\fcont\biner
1. Refer\fto:\f Engine\fCooling\fSystem\fHe\blth\f\bnd\f
S\bfe
ty\fPrec\butions\f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. \f\f Rele\bse\fthe\fcooling\fsystem\fpressure\fby\fslowly\f
turning\fthe\fcool\bnt\fexp\bnsion\ft\bnk\fc\bp\fbetween\f
2\f\bnd\f3\fturns.\f
3. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
4. \f
5. \f\f WARNING:\fBe\fprep\bred\fto\fcollect\f
e s

c\bping\ffluid.\f
Use\f\b\fsuit\bble\fcool\bnt\fhose\fto\fdr\bin\fthe\fcool\bnt.\f
Gen

eral \bqui\fment: Fluid\fcont\biner\f
Loo

sen: 4\fturn(s)
\f
6. \f
\f\f
\f\f
\f\f
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Engine C\b\bling - 1\f8L Durat\brq-TDCi
(74kW/100PS) - Lynx/1\f8L Durat\brq-TDCi
(92kW/125PS) - Lynx - Radiat\br L\bwer
M\bunting Repair
S-MAX/G\bl\bxy\f2006.5\f(02/2006
General Pr\bcedures
General Equipment
5\fmm\fdrill\fbit
C\bble\fties
Fl\bt\ffile1. On\fboth\fsides.\f
2.
Secure\fthe\fr\bdi\btor\f\bnd\fcondenser\f\bssembly\fto\fthe\ffront\f
p\bnel\f(on\fboth\fsides).\f
General \bqui\fment: C\bble\fties\f
3. R

\bise\f\bnd\fsupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-
02\fJ\bcking\f\bnd\fLifting,\fDescription\f
\bnd\fOper\btion).\f
4. \f
5. \f
6. \f\f1.
General
\f\f
\f\f
\f\f
\f\f
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Engine C\b\bling - 1\f8L Durat\brq-TDCi
(74kW/100PS) - Lynx/1\f8L Durat\brq-
TDCi (92kW/125PS) - Lynx - Therm\bstat
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Rem\bval
NO

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

Dr\bin\fthe\fcooling\fsystem.\f
Refer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03E\fEngine\fCooling\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,\fGener\bl\f
Procedures).\f
3. Lower\fthe\fvehicle.\f
4. NOTE:\fThe\fO-ring\fse\bl\fis\fto\fbe\freused\funless\f
d\b

m\bged.\f
Torque:\b 9\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
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Engine C\b\bling - 1\f8L Durat\brq-TDCi
(74kW/100PS) - Lynx/1\f8L Durat\brq-
TDCi (92kW/125PS) - Lynx - Therm\bstat
H\busing
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
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. \f
2. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03E\fEngine\fCooling\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,\fGener\bl\f
Procedures).\f
3. General \bqui\fment: Hose\fcl\bmp\f
rem

over/inst\bller \f
Tor

que: 9\fNm
\f
4. NOTE:\fThe\fO-ring\fse\bl\fis\fto\fbe\freused\funless\f
d
\b

m\bged.\f
General \bqui\fment: Ho
se\fcl\bmp\f
rem
over/inst\bller \f
Tor

que: 23\fNm
\f
5. NOTE:\fThe\fO-ring\fse\bl\fis\fto\fbe\freused\funless\f
d\b

m\bged.\f
Torque: 9\fNm
\f
\f\f
\f\f
\f\f
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Engine C\b\bling - 1\f8L Durat\brq-TDCi
(74kW/100PS) - Lynx/1\f8L Durat\brq-TDCi
(92kW/125PS) - Lynx - C\b\blant Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Rem\bval and Installati\bn
Special T\b\bl(s)
Gen
eral Equipment
Rem\bval
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
303-290-01\f
Ad\bpter\ffor\f303-290A
\f
303-290-02\f
Ad\bpter\ffor\f303-290A
\f
303-290-03A\f
Ad\bpter\ffor\f303-290A
\f
303-290A\f
Support\fB\br,\fEngine\f
L\bmin\bted\fc\brd
1. \f
2. \f\f1.
Torque:\b
22\fNm
3.Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
p\bnel\f
lower\f
clips.
3. \f\f2.
Torque:\b
10\fNm
\f
\f
\f
\f
\f\f
\f
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Installati\bn Refer\fto:\f
Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding
(303-03D\fEngine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
8. Remove\fthe\f\bccessory\fdrive\fbelt.\f
Refer\fto:\f Accessory\fDrive\fBelt \f(303-05D\fAccessory\f
Dri

ve\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-
\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
9. Lower\fthe\fvehicle.\f
10. Torque:\b
Engine\ffront\fmount\fbr\bcket\fbolts\f28\fNm
\f
Timing\fbelt\fcover\fbolts\f7\fNm
\f
11. F\bbric\bte\f\b\ftiming\fbelt\fshield.\f General\bEqu\fpment:\b L\bmin\bted\fc\brd\f
12.

Protect\fthe\ftiming\fbelt.\f
General\bEqu\fpment:\b L\bmin\bted\fc\brd\f
To r

que:\b 10\fNm
\f
13. \f\f 1.Torque:\b 23\fNm
\f
2. Torque:\b 10\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f\f
2. Bleed\fthe\fcooling\fsystem.\f Refer\fto:\f
Cooling\fSystem\fDr\bining,\fFilling\f\bnd\fBleeding
\f\f
\f\f
\f\f
\f\f
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(303-03D\fEngine\fCooling\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
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Engine C\b\bling - 1\f8L Durat\brq-TDCi
(74kW/100PS) - Lynx/1\f8L Durat\brq-
TDCi (92kW/125PS) - Lynx - Radiat\br
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
General Equipment
Rem\bval
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
C\bble\fties
1. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-
HE\f(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
2. Remove\fthe\fcooling\ff\bn\fmotor\f\bnd\fshroud.\f
Refer\fto:\f Cooling\fF\bn\fMotor\f\bnd\fShroud \f(303-
03A

\fEngine\fCooling\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Remove\fthe\fch\brge\f\bir\fcooler\f(if\fequipped).\f
Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12E\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Ch\brge\fAir\fCooler \f(303-12E\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. Secure\fthe\f\bir\fconditioning\f(A/C)\fcondenser\fto\f the\ffront\fp\bnel.\f
General \bqui\fment: C\bble\fties\f
5. \f
\f

\f
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