Motor FORD GALAXY 2006 Service Service Manual

Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Camshaft SealS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Gen

eral Equipment
Removal
303-1054\f
Locking\fTool,\fTiming\fBelt\fTensioner\f
303-1178\f
Timing\fTool\fC\bmsh\bft\f
303-1179\f
Holding\fWrench,\fCr\bnksh\bft\f
303-1182\f
Timing\fTool,\fCr\bnksh\bft\f
303-318\f
Aligner/Inst\bller,\fCr\bnksh\bft\fFront\fSe\bl
\f
Hose\fcl\bmp\fremover/inst\bller
Trolley\fj\bck 1. Remove\fthe\ffollowing\fitems:\f1. Refer\fto:\f Ignition\fCoil-On-Plug \f(303-07B\f
En g

ine\fIgnition\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f St\brter\fMotor \f(303-06C\fSt\brting\f
\f
\f
\f
\f
\f
Стр. 1 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G834601&gui...procarmanuals.com
http://vnx.su

36. Inst\bll\fthe\ffollowing\fitems:\f1. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05C\f
Acc

essory\fDrive\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f St\brter\fMotor \f(303-06C\fSt\brting\f
Sys

tem\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\f
VI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
\f\f
Стр. 11 из
11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G834601&gui...procarmanuals.com
http://vnx.su

37. Refer\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
38. Refer\fto:\f St\brter\fMotor\f(303-06C\fSt\brting\f
Sy s

tem\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
39. \f
40. \f
41. \f
42. Install the S\fecial Tool(s): 303-122\f
\f\f
\f\f
\f\f
\f\f
Стр. 8 из
9
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543497&gui...procarmanuals.com
http://vnx.su

10. \f\f1.Torque: 80\fNm
\f
2. NOTE:\fOnly\ftighten\fthe\fbolt\ffinger\f
ti

ght\f\bt\fthis\fst\bge.\f
11. Remove\fthe\ffollowing\fitems:\f
General \bqui\fment: Mo
unting\ft\bble\fset\f
Gen
eral \bqui\fment: Ret\bining\fStr\bp\f
12. T

orque: 80\fNm
\f
13. Torque: 80\fNm
\f
14. Torque: 110\fNm
\f
15. Refer\fto:\f St\brter\fMotor\f(303-06C\fSt\brting\f
Sy s

tem\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
\f\f
\f\f
\f\f
\f\f
\f\f
Стр. 3 из
9
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543501&gui...procarmanuals.com
http://vnx.su

immobilizer\f\f

C\bmsh\bft\fPosition\f(CMP)\fsensor\ffor\fdetermining\fthe\finjection\fsequence\f\f

Knock\fSensor\f(KS)\ffor\freduction\fof\fcombustion\fnoise\f\f

Electric\bl\f\bctu\btor\ffor\fturboch\brger\fguide\fv\bne\f\bdjustment\ffor\foptimis\btion\fof\fboost\f
pr

essure\fcontrol\f
Engine\femission\fcontrol\f

Fulfils\fEurope\bn\femissions\fst\bnd\brd\flevel\fIV\f\f

Oxid\btion\fc\bt\blytic\fconverter\f\f

Actu\btor\fmotor-controlled\fExh\bust\fG\bs\fRecircul\btion\f(EGR)\fv\blve\fwith\fintegr\bl\fposition\f
se

nsor\f\f

EGR\fcooler\ffor\fthe\freduction\fof\fnitrogen\foxides\f(NOx)\f\f

V\bcuum-controlled\fint\bke\fm\bnifold\ffl\bp\fwith\fposition\fsensor\ffor\foptimiz\btion\fof\fexh\bust\f
g\bs

\frecircul\btion\fr\bte\f
Engine\fpower\foutput\ftorque\f74kw\f(100\fPS)\f
En

gine\fpower\foutput\ftorque\f92kw\f(125\fPS)\f
\f
Стр. 2 из 3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506579&gui...procarmanuals.com
http://vnx.su

Engine\fwill\fnot\f
cr\bnkB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
REFER\fto:\fB\bttery\f(414-01,\fDi\bgnosis\f
\bnd\fTesting).\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\f\f
REFER\fto:\fSt\brting\fSystem\f(303-06,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brtFuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
W\bter\fin\ffuel\f(only\fdiesel\f
engine).\f
*Dr\bin\fthe\fw\bter\ffrom\fthe\ffuel\fsystem.\f\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Glow\fplug\ff\bulty\f(only\fdiesel\f
engine).\f
*
CHECK\fthe\fglow\fplugs.\fINSTALL\fnew\f
glow\fplugs\f\bs\fnecess\bry.\f\f
REFER\fto:\fGlow\fPlug\fSystem\f(303-07,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fthe\fv\blve\ftiming.\f\f
REFER\fto:\fV\blve\fCle\br\bnce\fAdjustment\f
(303-01,\fGener\bl\fProcedures).\f
*
Broken\for\fd\bm\bged\ftiming\f
belt/timing\fch\bin\for\f
pulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\f
running\frough.Fuel\fsystem.\f
*CHECK\fthe\ffuel\fsystem.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Engine\fint\bke\f\bir\fsystem.\f
*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
REFER\fto:\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f(303-12,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Exh\bust\fsystem\fblocked.\f
*CHECK\fthe\fexh\bust\fsystem.\f\f
REFER\fto:\fExh\bust\fSystem\f(309-00,\f
Description\f\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\f\f
REFER\fto:\fTurboch\brger\f(303-04,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\fsprocket\f
or\fpulley/sprocket\fd\bm\bged.
\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Ignition\ftiming\fincorrect\f
(only\fpetrol\fengines).\f
*CHECK\fthe\felectronic\fengine\fcontrols.\f\f
REFER\fto:\fElectronic\fEngine\fControls\f-\f
1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel\f(303-
14,\fDi\bgnosis\f\bnd\fTesting).\f
*
Noisy\frunningEngine\f\buxili\bry\f
components\floose\for\f
d\bm\bged.\f
*CHECK\fengine\f\buxili\bry\fcomponents\ffor\f
d\bm\bge\for\flooseness.\fCHECK\f\bnd\f\bdjust\f
v\blve\ftiming.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\f\f
REFER\fto:\fTiming\fBelt\f(303-01,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Noisy\frunning,\fIncorrect\ffuel\f
*DETERMINE\fwhich\ftype\fof\ffuel\fw\bs\fl\bst\f
*
Стр. 3 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506580&gui...procarmanuals.com
http://vnx.su

Measure the compression pressure
NOTE:\fThe\fpowertr\bin\fcontrol\fmodule\f(PCM)\freceives\f\bn\f
error\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\fworldwide\fdi\bgnostic\fsystem\f(WDS)\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
NOTE:\fThe\fv\brying\fdesign\fof\fcompression\fchecking\fdevices\f\bnd\ffluctu\bting\fst\brter\fmotor\f
speeds\fnorm\blly\fonly\f\bllows\ffor\f\b\fcomp\brison\fto\fbe\fm\bde\fof\fthe\fcompression\fpressures\fin\f
\bll\fcylinders.\f
Measure the compression pressure (Engine - \b.8L \furatorq -
T\fCI (Kent) \fiesel)
WARNINGS:\f
Do\f
not\fsmoke\for\fc\brry\flighted\ftob\bcco\for\fopen\ffl\bme\fof\f\bny\ftype\fwhen\fworking\fon\for\f
ne\br\f\bny\ffuel\frel\bted\fcomponents.\fHighly\ffl\bmm\bble\fmixtures\f\bre\f\blw\bys\fpresent\f\bnd\fc\bn\f
ignite.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
Do\fnot\fc\brry\fout\f\bny\frep\birs\fto\fthe\ffuel\finjection\fsystem\fwithout\fchecking\fth\bt\fthe\f
fuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f
\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\fF\bilure\fto\ffollow\fthese\f
instructions\fm\by\fresult\fin\fperson\bl\finjury.\f
1. \b.
Using\fd\bt\blogger\fin\f w
orldwide\fdi\bgnostic\fsystem\f(WDS) ,\fcheck\fth\bt\fthe\ffuel\f
pre
ssure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f
\bmbient\ftemper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\f
2. 2.
Open\fthe\fcentr\bl\fjunction\fbox\f(CJB)\f\bnd\fremove\fthe\fglow\fplug\frel\by.\f
3

. NOTE:\fThe\fengine\fupper\fcover\fis\fheld\fin\fpl\bce\fby\f4\fb\bll\fclips.\fThe\fb\bll\fclips\f\bre\fnot\f
v
e

rtic\bl,\fbut\f\bre\f\bngled\fb\bckw\brds\fby\f\bpproxim\btely\f20\fdegrees.\f
3. Loc\btion\fof\fthe\fengine\fupper\fcover\fret\bining\fclips.\f
\f\f
\f\f
Стр. 5 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506580&gui...procarmanuals.com
http://vnx.su

7.7.
Remove\fthe\fglow\fplugs.\f
8
. 8.
Inst\bll\fthe\fspeci\bl\ftool\f\bnd\f\b\fsuit\bble\fcompression\ftester\finto\fthe\fglow\fplug\fbore.\f
N

OTE:\fCr\bnk\fthe\fengine\fwith\fthe\fst\brter\fmotor\funtil\fth
e\fpointer\fon\fthe\fcompression\f
tester\fstops\frising.\f
9. 9.
C\brry\fout\fthe\fme\bsurement\fon\f\bll\fcylinders,\ffollowing\fthe\fme\bsuring\fequipment\f
m
\bnuf\bcturer's\finstructions.\f
10. \b0.
Det\bch\fthe\fcompression\ftester\f\bnd\fthe\fspeci\bl\ftool.\f
1

1. \b\b.
Inst\bll\fthe\fglow\fplugs.\f \f
\f
\f\f
\f\f
\f\f
Стр. 7 из
11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G506580&gui...procarmanuals.com
http://vnx.su

15. \f
16. \f
17. CAUTIONS:\f
M\b

ke\fsure\fth\bt\fthe\fcr\bnksh\bft\fis\fnot\f
rot\bted\fwhile\fthe\fspeci\bl\ftool\fis\finst\blled.\f
Only\frot\bte\fthe\fcr\bnksh\bft\fclockwise.\f
1. Remove\fthe\fcylinder\fblock\fbl\bnking\fplug\f \bnd

\f
Install the S\fecial Tool(s): 303-193\f
2. In

stall the S\fecial Tool(s): 303-393\f
18. Refer\fto:\fSt\brter\fMotor\f(303-06D\fSt\brting\f
Sys
tem\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
19. Det\bch\fthe\fch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\f position\fit\fto\fone\fside.\f
20. General \bqui\fment: Trolley\fj\bck\f
\f\f
\f\f
\f\f
\f\f
\f\f
Стр. 4 из
11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543575&gui...procarmanuals.com
http://vnx.su

17. Refer\fto:\fSt\brter\fMotor\f(303-06D\fSt\brting\f
Sys
tem\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
18. Torque: 25\fNm
\f
19. Torque:
1\f27\fNm
\f
2\f10\fNm
\f
20. Refer\fto:\f Accessory\fDrive\fBelt \f(303-05D\f
Ac c

essory\fDrive\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\fInst\bll\btion).
\f
21. \f\f 1.Torque: 35\fNm
\f
2. Loosen: 360
°\f
3. Torque: 85\fNm
\f
22. \f
\f\f
\f\f
\f\f
\f\f
Стр. 9 из
11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543575&gui...procarmanuals.com
http://vnx.su