clock FORD GALAXY 2006 Service Workshop Manual

Disconnect\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f(PCV)\f
bre\bther\fhose\ffrom\fthe\fint\bke\fm\bnifold\fPCV\fv\blve.\f

Press\fin\fthe\frele\bse\fclip.\f
2
Remove\fthe\fturboch\brger\fint\bke\fpipe\fsupport\f
br\bcket\fret\bining\fbolt.\f3
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
4
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f5
Det\bch\fthe\fturboch\brger\fint\bke\fpipe.\f6
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f7
\f\f
\f\f
\f\f
\f\f
\f\f
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Inspect\fthe\fturboch\brger\foil\fsupply\fpipe\funion\ffor\f
block\bge.\f2
Is\fthe\foil\fsupply\fpipe\funion\fnon\freturn\fv\blve\ffree\fto\f
move\f\bnd\fthe\funion\ffree\ffrom\fblock\bge?\f\f
Yes INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bn d

\fControls\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\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No INSTALL\f\b\fnew\fturboch\brger\f\bnd\foil\fsupply\fpipe\f
non\freturn\fv\blve.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\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\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER
NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
1
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f2
NOTE:\fDisc\brd\fthe\fg\bsket.\f
Remove\fthe\fturboch\brger\foil\freturn\fpipe.\f
3
\f\f
\f\f
Стр. 6 из 11
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R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
2
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f3
Disconnect\fthe\fv\bcuum\fline\ffrom\fthe\fv\bne\f
\bdjustment\fdi\bphr\bgm\funit.\f4
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f5
Oper\bte\fthe\fspeci\bl\ftool\funtil\f\b\fv\bcuum\fof\f35\fKp\b\f
is\f\bchieved.\fMe\bsure\fthe\fdist\bnce\ftr\bvelled\fby\fthe\f
v\bne\f\bdjustment\fdi\bphr\bgm\funit\f\bctu\btor\frod.\f6
Does\fthe\fv\bne\f\bdjustment\fdi\bphr\bgm\funit\f\bctu\btor\frod\f
move\fbetween\f9\f\bnd\f11\fmm?\f
Yes GO\fto\fC3 .\f\f
No C

HECK\ffor\fsigns\fof\fd\bm\bge\for\fsigns\fof\fforeign\f
m\bteri\bl\fin\fthe\fturboch\brger\fv\bnes.\fINSTALL\f\b\fnew\f
turboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\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\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
\f\f
\f\f
\f\f
\f\f
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With\fthe\fengine\f\bt\fidle,\fis\fthe\fvolt\bge\fgre\bter\fth\bn\f10\f
volts?\f
Yes INSTALL\f\b\fnew\fturboch\brger\fv\bcuum\fcontrol\f
solenoid.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No Continue\fthe\fdi\bgnostic\fof\fthe\fengine\fm\bn\bgement\f
system\fusing\fWDS.\f
C6: CHECK THE VACUUM DIAPHRAGM UNIT FOR LEAKS
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
1
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f2
Disconnect\fthe\fv\bcuum\fline\ffrom\fthe\fv\bcuum\f
di\bphr\bgm\funit.\f3
Inst\bll\fthe\fspeci\bl\ftool\fto\fthe\fv\bne\f\bdjustment\f
di\bphr\bgm\funit.\f4
Oper\bte\fthe\fspeci\bl\ftool\f\bnd\fobserve\fthe\fre\bding.\f5
Does\fthe\fspeci\bl\ftool\fhold\fv\bcuum?\f
Yes
INSTALL\f\b\fnew\fv\bcuum\fline.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
No
\f\f
\f\f
\f\f
\f\f
Стр. 10 из
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Electro\bic E\bgi\be \fo\btrols - 2.0L Duratec-
HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4 -
\fra\bkshaft Positio\b (\fKP) Se\bsor
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Special Tool(s)
Removal
I\b

stallatio\b
303-1390\f
Alignment\fTool,\fCr\bnksh\bft\fPosition\fSensor
\f
1. \f\f 1. CAUTION:\fOnly\frot\bte\fthe\f
cr

\bnksh\bft\fclockwise.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\finst\bll\btion\f
m\brks\f\bre\f\bligned.\f
2. Bolt\fM6x18\fmm\f
1. Special\bTool(\f):\b 303-1390\f
Tor
que:\b 7\fNm
\f
2. \f
\f
\f
\f\f
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Electro\bic E\bgi\be \fo\btrols - 2.3L Duratec-
HE (118kW/160PS) - MI4 - \fra\bkshaft
Positio\b (\fKP) Se\bsor
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Special Tool(s)
Removal
I\b

stallatio\b
303-1390\f
Alignment\fTool,\fCr\bnksh\bft\fPosition\fSensor
\f
1. \f\f 1. CAUTION:\fOnly\frot\bte\fthe\f
cr

\bnksh\bft\fclockwise.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\finst\bll\btion\f
m\brks\f\bre\f\bligned.\f
2. Bolt\fM6x18\fmm\f
1. Special\bTool(\f):\b 303-1390\f
Tor
que:\b 7\fNm
\f
2. \f
\f
\f
\f\f
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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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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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\bnd\fdo\fthey\f\bll\fh\bve\fthe\fs\bme\flength?\f
Yes GO\fto\fE21 .\f\f
N\f
I

NSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E21: 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
E22: ENGINE SELECTION – PETROL ENGINES
1
Does\fthe\fvehicle\fh\bve\f\b\f2.0L\fpetrol\fengine\for\f\b\f2.5L\f
petrol\fengine?\f
Yes Vehicles\fwith\f\b\f2.0L\fpetrol\fengine GO\fto\fE23.\f
Veh

icles\fwith\f\b\f2.5L\fpetrol\fengine GO\fto\fE29.\f\f
E23: 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\fE25 .\f\f
E24: 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
1
\f\f
\f\f
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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\fE28 .\f\f
E28: 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
The\fdu\bl\fm\bss\fflywheel\fis\fOK.\f
N\f INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E29: 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\fE31 .\f\f
E30: 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\f1
\f\f
\f\f
\f\f
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