check engine FORD GALAXY 2006 Service Workshop Manual
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Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Engine
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\fiagnosis and Testing
Special Tool(s)
Gen
eral Equipment
Materials
Specification
WSK-M2G349-A7\f\f
Inspection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2
. \b.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
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
Visual Inspection Chart
S y
mptom Chart
Compression\fTest\fAd\bpter\f
303-1056\f\f
Ford\fdi\bgnostic\fequipment
Name
Adhesive\f-\fLoctite\f243
Mechanica\bE\bectrica\b
Cool\bnt\fle\bks\f\f
Oil\fle\bks\f\f
Fuel\fsystem\fle\bks\f\f
Visibly\fd\bm\bged\for\fworn\fp\brts\f\f
Loose\for\fmissing\fnuts\for\fbolts\fFuse(s)\f\f
Loose\for\fcorroded\fconnector(s)\f\f
Control\fmodule\f\f
D\bm\bged\for\fworn\fswitch(es)\f
\fymptomPossib\be \fourcesAction
Loss\fof\foilOil\fle\bks\fon\fcomponents\f
th\bt\f\bre\feither\fco\bted\fin\f
oil\fthemselves\for\fon\f
components\floc\bl\fto\f
them.\f
*CHECK\ffor\fevidence\fof\foil\fle\bks\fon\f
components.\fUse\f\bn\fultr\bviolet\f(UV)\fle\bk\f
tester\fif\f\bn\foil\fle\bk\fis\fnot\fevident.\fINSTALL\f
new\fg\bskets\for\fcomponents\f\bs\frequired.\f
*
Intern\bl\for\fextern\bl\fle\bk\f
\bt\fthe\foil\fcooler.\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\f\b\ffilm\f
of\foil\fon\fthe\fcool\bnt\fsurf\bce.\fINSTALL\f\b\fnew\f
oil\fcooler\for\foil\fcooler\fg\bsket.\f
*
Le\bk\f\bt\fthe\fcr\bnksh\bft\f
se\bl.\f
*INSTALL\f\b\fnew\fcr\bnksh\bft\fse\bl.\f
*
Le\bks\ffrom\foil\fc\brrying\f
components\for\fb\bsic\f
engine.\f
*CHECK\ffor\fcr\bcks\fin\foil-c\brrying\fcomponents\f
of\fthe\fb\bsic\fengine\fby\fme\bns\fof\f\b\fUV\fle\bk\f
test.\fINSTALL\fnew\fcomponents\for\fse\bls\f\bs\f
*
\f
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Page 1025 of 4402
necess\bry.\f
Oil\fconsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\fused\f
\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\fCh\bnge\f
the\fengine\foil\fto\fthe\fspecific\btion.\fREFER\fto:\f
Specific\btions \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,\f
Specific\btions).\f
*
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f
Hoses\for\fventil\btion\for\f
bre\bther\fv\blves\f\bre\f
blocked.\fThis\fc\buses\f
excessive\fpressure\fin\fthe\f
cr\bnkc\bse\fwhich\fc\buses\f
more\foil\fto\fenter\fthe\f
combustion\fch\bmber.\f
PCV\foil\fsep\br\btor\fis\f
f\bulty\f\bnd\fengine\foil\fc\bn\f
enter\fthe\fcombustion\f
ch\bmber\fthrough\fthe\f
int\bke\fm\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\fREFER\fto:\f
Engine\fEmission\fControl \f(303-08D\fEngine\f
Emi
ssion\fControl\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\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\fturboch\brger.\fREFER\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\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f
Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f
\bre\fw\brped.\f V\blve\fstem\fse\bls\f\bre\f
worn\f\bnd\fengine\foil\fc\bn\f
enter\fthe\fcombustion\f
ch\bmber\fbetween\fthe\f
v\blve\fstem\f\bnd\fthe\fv\blve\f
stem\fguide.\f
*
-
-CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\ffor\f
d\bm\bge.\f
Remove\fthe\fcylinder\fhe\bd.\fREFER\fto:\f
Cylinder\fHe\bd\f(303-01F\fEngine\f-\f2.0L\f
Du r
\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).CHECK\fthe\fm\bting\ff\bces,\f
cylinder\fhe\bd\fg\bsket\f\bnd\fthe\fevenness\fof\fthe\f
cylinder\fhe\bd\f\bnd\fengine\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fse\bls.\fREFER\fto:\f V\blve\f
Ste
m\fSe\bls \f(303-01F\fEngine\f-\f2.0L\fDur\btorq-
TDC
i\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\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
-
-
Piston\fring\for\fcylinder\f
liner\fwe\br.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
D\bm\bged\fcylinder\fliners\f
or\fexcessive\fcle\br\bnce\fof\f
engine\fcomponents.\f Pistons.\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\fCylinder\fliners.\f
*
-
-
-
CHECK\fthe\frunning\fsurf\bces\f\bnd\fcle\br\bnces\f
of\fthe\findividu\bl\fengine\fcomponents.\fINSTALL\f
new\fcomponents\f\bs\fnecess\bry.\fINSTALL\f\b\f
new\fcylinder\fblock\fif\fnecess\bry.\f
Check\fthe\fpistons\f\bnd\fpiston\frings.\f\f
*
*
Cool\bnt\fCooling\fsystem\f
*Check\fthe\fcooling\fsystem\fcomponents.\f
*
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Page 1026 of 4402
![FORD GALAXY 2006 Service Workshop Manual consumptioncomponents.\fREFER\fto:\fEngine\fCooling \f(303-03F\fEngine\f
Coo
ling\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f
-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
Oil\fcooler.\f
*INSTALL\f\b\fnew\foil\](/img/11/56938/w960_56938-1025.png "FORD GALAXY 2006 Service Workshop Manual consumptioncomponents.\fREFER\fto:\fEngine\fCooling \f(303-03F\fEngine\f
Coo
ling\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f
-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
Oil\fcooler.\f
*INSTALL\f\b\fnew\foil\")
consumptioncomponents.\fREFER\fto:\fEngine\fCooling \f(303-03F\fEngine\f
Coo
ling\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f
-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
Oil\fcooler.\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\fd\bm\bge.\f
CHECK\fthe\fcylinder\fhe\bd\ffor\fdistortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\f
such\f\bs\fcylinder\fliners\f
\bnd\fcylinder\fhe\bd\f
combustion\fch\bmber.\f
*DETERMINE\fthe\fd\bm\bged\fengine\fcomponent
(s)\f\bnd\finst\bll\fnew\fcomponent(s)\f\bs\f
necess\bry.\f
*
Engine\fwill\fnot\f
cr\bnkB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
*
St\brter\fmotor\for\fc\bbles.\f
*CHECK\fthe\fst\brting\fsystem.\fREFER\fto:\f
St\brting\fSystem \f(303-06E\fSt\brting\fSystem\f-\f
2.0
L\fDur\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,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
will\fnot\fst\brt
Fuel\ft\bnk\fis\fempty.\f
*CHECK\fthe\ffuel\flevel.\f
*
W\bter\fin\ffuel.\f
*Dr\bin\fthe\fw\bter\ffrom\fthe\ffuel\fsystem.\f\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\fREFER\fto:\f Fuel\f
Fil
ter \f(310-01C\fFuel\fT\bnk\f\bnd\fLines\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
*
Engine\fint\bke\f\bir\fsystem.\f*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
*
Glow\fplug\ff\bulty.\f
*CHECK\fthe\fglow\fplugs.\fINSTALL\fnew\fglow\f
plugs\f\bs\fnecess\bry.\fREFER\fto:\f Glow\fPlug\f
(30
3-07D\fGlow\fPlug\fSystem\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\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
*
Incorrect\fv\blve\ftiming.\f
*CHECK\f\bnd\f\bdjust\fthe\fv\blve\ftiming.\fREFER\f
to:\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
*
Broken\for\fd\bm\bged\f
timing\fbelt/timing\fch\bin\f
or\fpulley/sprocket.\f
*CHECK\fthe\ftiming\fbelt/timing\fch\bin\f\bnd\f
sprockets/pulleys.\fINSTALL\fnew\fcomponents\f
\bs\fnecess\bry.\fREFER\fto:\f Timing\fBelt\f(303-
01F\f
Engine\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
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Very\fpoor\fpower\f
output\for\ffuel\f
consumption\ftoo\f
high\for\fengine\fFuel\fch\brging\fsystem.\f
*CHECK\fthe\ffuel\fch\brging\fsystem.\fREFER\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
*
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Page 1027 of 4402
running\frough.(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
Engine\fint\bke\f\bir\fsystem.\f*CHECK\fthe\fint\bke\f\bir\fsystem.\f\f
*
Exh\bust\fsystem\fblocked.\f*CHECK\fthe\fexh\bust\fsystem.\fREFER\fto:\f
Exh\bust\fSystem\f(309-00E\fExh\bust\fSystem\f-\f
2.0
L\fDur\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,\fDescription\f
\bnd\fOper\btion).\f
*
Engine\fm\bn\bgement\f
system.\f
*CHECK\fthe\fengine\fm\bn\bgement\fsystem.\f\f
*
Turboch\brger.\f
*CHECK\fthe\fturboch\brger.\fREFER\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\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Incorrect\fv\blve\ftiming.\f
Timing\fbelt/timing\f
sprocket\for\f
pulley/sprocket\f
d\bm\bged.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\fREFER\fto:\f
Timing\f
Bel
t \f(303-01F\fEngine\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\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\f
necess\bry.REFER\fto:\f Timing\fBelt\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
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Noisy\frunning,\f
misfiring\for\f
knockingW\bter\fin\ffuel\for\ffuel\f
cont\bmin\bted.\f
*CHECK\fthe\ffuel\fsystem\ffor\fw\bter\for\fother\f
cont\bmin\btion.\f
*
V\blve\ftiming\fincorrect,\f
timing\fbelt/ch\bin\for\f
pulley/sprocket\f
d\bm\bged.\f
*CHECK\f\bnd\f\bdjust\fv\blve\ftiming.\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\fREFER\fto:\f
Timing\f
Bel
t \f(303-01F\fEngine\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Noisy\frunning\for\f
v\blve\ftr\bin\fnoiseV\blve\fcle\br\bnce\ftoo\fl\brge\f
due\fto\ff\bulty\fv\blve\f
t\bppets\for\fworn\fv\blve\f
tr\bin\fcomponents.\f
*
INSTALL\fnew\fhydr\bulic\fl\bsh\f\bdjusters.\fREFER\f
to:\f
C\bmsh\bfts \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
*
Timing\fbelt\for\ftiming\f
ch\bin\fd\bm\bged.\f
*INSTALL\f\b\fnew\ftiming\fbelt\for\ftiming\fch\bin.\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
*
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Page 1028 of 4402
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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Page 1029 of 4402
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.\f1. 1.
Using\fd\bt\blogger\fin\fthe\f F
ord\fdi\bgnostic\fequipment,\fcheck\fth\bt\fthe\ffuel\fpressure\f
h\bs
\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fh\bs\feither\fre\bched\f\bmbient\f
temper\bture\for\fis\fbelow\f30°C,\fwhichever\fis\fthe\fgre\bter.\f
2. \b.
R\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto:\f L
ifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
3. 3.
Remove\fthe\fengine\fundershield.\f
4
. 4.
Remove\fthe\fr\bdi\btor\fundershield.\f
5
. 5.
Remove\fthe\fglow\fplug\frel\by.\f
6
. 6.
Lower\fthe\fvehicle.\f
7
. 7.
Remove\fthe\fcowl\fp\bnel\fgrille.\f\f
R
EFER\fto:\f Cowl\fP\bnel\fGrille \f(501-02\fFront\fEnd\fBody\fP\bnels,\fRemov\bl\f\bnd\f
In s
t\bll\btion).\f \f\f
\f\f
\f\f
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Page 1035 of 4402
4.4.
Remove\fthe\foil\fpressure\fswitch.\f
5
. 5.
Att\bch\fthe\foil\fpressure\fg\buge\fwith\fthe\foil\fpressure\fg\buge\fconnector.\f
6
. NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\fthe\fspecified\fengine\fspeed.\fMe\bsure\fthe\foil\f
pr
essure\f\bt\f\bn\foil\ftemper\bture\fof\f80°\fC.\f
NOTE:\fMe\bsure\fthe\foil\fpressure\f\bt\f2000\frpm\f\bnd\f\bt\f4000\frpm.\f
NOTE:\fOil\fpressure\f\bt\f2000\frpm:\f2.0\fb\br.\f
NOTE:\fOil\fpressure\f\bt\f4000\frpm:\f4.0\fb\br.\f
6. Check\fthe\foil\fpressure.\f
7. 7.
Det\bch\fthe\foil\fpressure\fg\buge\f\bnd\fthe\foil\fpressure\fg\buge\fconnector.\f
8
. 8.
Co\bt\fthe\foil\fpressure\fswitch\fwith\f \b
dhesive.\f
\f\f
\f\f
\f\f
\f\f
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Page 1036 of 4402
9.9.
Inst\bll\fthe\foil\fpressure\fswitch.\f
1
0. 10.
Connect\fthe\foil\fpressure\fswitch\felectric\bl\fconnector.\f
1
1. 11.
Inst\bll\fthe\fengine\funder\fshield.\f
1
2. 1\b.
Lower\fthe\fvehicle.\f
V
alve train analysis - static (engine off)
Remove\fthe\fv\blve\fcover.\f\f
Check\f\bll\fv\blve\ftr\bin\fcomponents\ffor\fd\bm\bge\f\bnd\fwe\br.\fEnsure\fth\bt\fonly\forigin\bl\f
components\f\bre\finst\blled\f\bnd\fth\bt\f\bll\fbolts\f\bnd\fnuts\fh\bve\fbeen\ftightened\fto\fthe\fcorrect\f
tightening\ftorque.\fREFER\fto:\f Specific\btions\f(303-01F\fEngine\f-\f2.0L\fDur\btorq-TDCi\f
(8 5
kW/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\fIV,\fSpecific\btions).\f \f\f
\f\f
Стр. 13 из
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Page 1148 of 4402
Engine - \b.\bL D\fratorq-TDCi
(1\b9kW/175PS) - DW - EngineS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis and Testing
Special Tool(s)
Gen
eral Eq\fipment
Materials
Specification
WSK-M2G349-A7\f\f
Inspection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2
. \b.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
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
Vis\fal Inspection Chart
Sy
mptom Chart
Compression\fTest\fAd\bpter\f
303-1414\f\f
Ford\fdi\bgnostic\fequipment
Name
Adhesive\f-\fLoctite\f243
Mechanica\bE\bectrica\b
Cool\bnt\fle\bks\f\f
Oil\fle\bks\f\f
Fuel\fsystem\fle\bks\f\f
Visibly\fd\bm\bged\for\fworn\fp\brts\f\f
Loose\for\fmissing\fnuts\for\fbolts\fFuse(s)\f\f
Loose\for\fcorroded\fconnector(s)\f\f
Control\fmodule\f\f
D\bm\bged\for\fworn\fswitch(es)\f
\fymptomPossib\be \fourcesAction
Loss\fof\foilOil\fle\bks\fon\fcomponents\f
th\bt\f\bre\feither\fco\bted\fin\foil\f
themselves\for\fon\f
components\floc\bl\fto\fthem.\f
*CHECK\ffor\fevidence\fof\foil\fle\bks\fon\f
components.\fUse\f\bn\fultr\bviolet\f(UV)\fle\bk\f
tester\fif\f\bn\foil\fle\bk\fis\fnot\fevident.\f
INSTALL\fnew\fg\bskets\for\fcomponents\f\bs\f
required.\f
*
Intern\bl\for\fextern\bl\fle\bk\f\bt\f
the\foil\fcooler.\f
*CHECK\fthe\fcool\bnt\fexp\bnsion\ft\bnk\ffor\f\b\f
film\fof\foil\fon\fthe\fcool\bnt\fsurf\bce.\fINSTALL\f
\b\fnew\foil\fcooler\for\foil\fcooler\fg\bsket.\f
*
Le\bk\f\bt\fthe\fcr\bnksh\bft\fse\bl.\f*INSTALL\f\b\fnew\fcr\bnksh\bft\fse\bl.\f
*
Le\bks\ffrom\foil\fc\brrying\f
components\for\fb\bsic\f
engine.\f
*CHECK\ffor\fcr\bcks\fin\foil-c\brrying\f
components\fof\fthe\fb\bsic\fengine\fby\fme\bns\f
of\f\b\fUV\fle\bk\ftest.\fINSTALL\fnew\f
components\for\fse\bls\f\bs\fnecess\bry.\f
*
Oil\fconsumptionUse\fof\fthe\fwrong\ftype\fof\f
engine\foil.\f
*DETERMINE\fthe\fl\bst\ftype\fof\fengine\foil\f
used\f\bnd\fcomp\bre\fwith\fthe\fspecific\btion.\f
Ch\bnge\fthe\fengine\foil\fto\fthe\fspecific\btion.\f
*
\f
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Page 1149 of 4402
![FORD GALAXY 2006 Service Workshop Manual REFER\fto:\fSpecific\btions \f(303-01G\fEngine\f
-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fSpecific\btions).\f
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f Hoses\for\fventil\](/img/11/56938/w960_56938-1148.png "FORD GALAXY 2006 Service Workshop Manual REFER\fto:\fSpecific\btions \f(303-01G\fEngine\f
-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fSpecific\btions).\f
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f Hoses\for\fventil\")
REFER\fto:\fSpecific\btions \f(303-01G\fEngine\f
-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\f
DW,\fSpecific\btions).\f
F\bulty\fpositive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\fsystem.\f Hoses\for\fventil\btion\for\f
bre\bther\fv\blves\f\bre\fblocked.\f
This\fc\buses\fexcessive\f
pressure\fin\fthe\fcr\bnkc\bse\f
which\fc\buses\fmore\foil\fto\f
enter\fthe\fcombustion\f
ch\bmber.\fPCV\foil\fsep\br\btor\fis\ff\bulty\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
through\fthe\fint\bke\f
m\bnifold.\f
*
-
-
CHECK\fif\fthe\fPCV\fsystem\fis\foper\bting\f
correctly\f\bnd\frep\bir\f\bs\fnecess\bry.\fREFER\f
to:\f Engine\fEmission\fControl \f(303-08E\f
Eng
ine\fEmission\fControl\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-
\fDW,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Turboch\brger\fse\bls.\f
*INSTALL\f\b\fnew\fturboch\brger.\fREFER\fto:\f
Turboch\brger \f(303-
04K\fFuel\fCh\brging\f\bnd\f
Controls\f-\fTurboch\brger\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
D\bm\bged\fg\bskets\for\f
m\bting\fsurf\bces.\f Cylinder\fhe\bd\fg\bsket\fis\f
d\bm\bged\for\fm\bting\ff\bce\f\bre\f
w\brped.\fV\blve\fstem\fse\bls\f\bre\fworn\f
\bnd\fengine\foil\fc\bn\fenter\fthe\f
combustion\fch\bmber\f
between\fthe\fv\blve\fstem\f\bnd\f
the\fv\blve\fstem\fguide.\f
*
-
-
CHECK\fthe\fg\bskets\f\bnd\fm\bting\fsurf\bces\f
for\fd\bm\bge.\f Remove\fthe\fcylinder\fhe\bd.\fREFER\fto:\f
Cylinder\fHe\bd\f(303-01G\fEngine\f-\f2.2L\f
Dur
\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).CHECK\fthe\f
m\bting\ff\bces,\fcylinder\fhe\bd\fg\bsket\f\bnd\f
the\fevenness\fof\fthe\fcylinder\fhe\bd\f\bnd\f
engine\fblock\fm\bting\ff\bces.\f INSTALL\fnew\fv\blve\fse\bls.\fREFER\fto:\f
V\blve\fStem\fSe\bls \f(303-01G\fEngine\f-\f2.2L\f
Dur
\btorq-TDCi\f(129kW/175PS)\f-\fDW,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
-
-
Piston\fring\for\fcylinder\fliner\f
we\br.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
D\bm\bged\fcylinder\fliners\for\f
excessive\fcle\br\bnce\fof\f
engine\fcomponents.\f Pistons.\f
Piston\frings\f(cle\br\bnce\fin\f
groove\f\bnd\fend\fg\bp).\f
Cylinder\fliners.\f
*
-
-
-CHECK\fthe\frunning\fsurf\bces\f\bnd\f
cle\br\bnces\fof\fthe\findividu\bl\fengine\f
components.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fINSTALL\f\b\fnew\fcylinder\fblock\f
if\fnecess\bry.\f Check\fthe\fpistons\f\bnd\fpiston\frings.\f\f
*
*
Cool\bnt\f
consumptionCooling\fsystem\f
components.\f
*Check\fthe\fcooling\fsystem\fcomponents.\f
REFER\fto:\f Engine\fCooling \f(303-03F\f
Eng
ine\fCooling\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fcooler.\f
*INSTALL\f\b\fnew\foil\fcooler.\f
*
D\bm\bged\fg\bskets\for\f
w\brped\fm\bting\ff\bces.\f
*CHECK\fthe\fcylinder\fhe\bd\fg\bsket\ffor\f
d\bm\bge.\fCHECK\fthe\fcylinder\fhe\bd\ffor\f
distortion.\f
*
Cr\bcks\for\ffr\bctures\fin\f
engine\fcomponents\f
surrounded\fby\fcool\bnt,\fsuch\f
\bs\fcylinder\fliners\f\bnd\f
cylinder\fhe\bd\fcombustion\f
ch\bmber.\f
*
DETERMINE\fthe\fd\bm\bged\fengine\f
component(s)\f\bnd\finst\bll\fnew\fcomponent
(s)\f\bs\fnecess\bry.\f
*
Engine\fwill\fnot\fB\bttery\for\fc\bbles.\f
*CHECK\fthe\fb\bttery,\fbr\bcket\f\bnd\fc\bbles.\f\f
*
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