fuel filter FORD GALAXY 2006 Service Repair Manual

Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.2L
Dur\btorq-TDCi (129kW/175PS) - DW -
Fuel Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
1.NOTE:\fV\bcuum\f\bny\fforeign\fm\bteri\bl\ffrom\fthe\f
fu

el\fpump\f\bnd\ffuel\fr\bil\funions\fbefore\fse\bling\f
the\funions\fwith\fbl\bnking\fc\bps.\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\f
cont\bin\finst\bll\btion\fdet\bils.\f
Refer\fto:\f Di
esel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre
c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01\f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
Refer\fto:\f Air\fCle\bner \f(303-12F\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
3. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in
st\blled.\f\f
Torque:\b 1:
\f10\fNm
\f
2:\f8\fNm
\f
3:\f10\fNm
\f
4. Torque:\b 8\fNm
\f
5. CAUTIONS:\f
M\b
ke\fsure\fth\bt\fthe\f\bre\b\f\bround\fthe\f
component\fis\fcle\bn\f\bnd\ffree\fof\fforeign\f
m\bteri\bl.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f\f
Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
6. CAUTIONS:\f
Us e\f\bn\fopen-ended\fwrench\fto\fprevent\f
\f\f
\f\f
\f\f
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Pi\fpoi\ft Tests
Poor\fengine\f
perform\bnce\fW\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f V\bcuum\fline(s).\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Ch\brge\f\bir\fcooler\f
pipes\f Ch\brge\f\bir\fcooler\f
r\bdi\btor\f Ch\brge\f\bir\fcooler\f
w\bter\fpump\f Ch\brge\f\bir\fcooler\f
*
*
*
*REFER\fto\f
in\fthis\fsection. \f
*
Air\fcle\bner\fint\bke\f
pipe\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
w\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fw\bsteg\bte\fcontrol\fv\blve\funit\f\bctu\btor\frod\f
h\bs\fnot\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-
04H\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Ignition\fsystem.\f
*CHECK\fthe\fignition\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\fch\brging\fsystem.\f*CHECK\fthe\ffuel\fch\brging\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\f\bir\fcle\bner.\f\f
REFER\fto:\f
Air\fCle\bner \f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f2
Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No
GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\f1
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - Turboch\brger -
1.8L Dur\btorq-TDCi (74kW/100PS) -
Ly\fx/1.8L Dur\btorq-TDCi (92kW/125PS) -
Ly\fx - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
I\fst\bll\btio\f 1. Remove\fthe\ffollowing\fitems:\f

Refer\fto:\f C\bt
\blytic\fConverter \f(309-00D\fExh\bust\f
System\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\fAir\fCle\bner \f(303-12D\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\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).
2. NOTE:\fNote\fthe\fposition\fof\fthe\fcomponent\fbefore\f
re
mov\bl.\f
Disc\brd\fthe\fcl\bmp.\f
3.
\f\f 3. Disc\brd\fthe\fnut.\f
4. Disc\brd\fthe\foil\fsupply\ftube.\f
1.
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\finst\blled.
Torque:\b 35\fNm\f
\f\f
\f
\f\f
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Intake \bir Di\ftribution and Filtering - 2.0L
Duratec-HE (107kW/145PS) - MI4/2.0L
Duratec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Duratec-HE (118kW/160PS) -
MI4 - Intake \bir Di\ftribution and Filtering
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcription and Operation
\f\f
De\fcription
Electronic\fthrottle\fbody\f
Int\bke\f\bir\freson\btor\f
Air\fcle\bner\fto\fint\bke\f\bir\freson\btor\fpipe\f
Air\fcle\bner\fcover\f
Air\fcle\bner\felement\f
Air\fcle\bner\fhousing\f
Noise,\fvibr\btion\f\bnd\fh\brshness\f(NVH)\ffo\bm\f
Air\fcle\bner\fint\bke\fpipe\f
Air\fcle\bner\foutlet\fpipe\f
Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fhose\f
Item
1
2
3
4
5
6
7
8
9
10
\f
Part Number -
-
-
-
-
-
-
-
-
-
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Intake \bir Di\ftribution and Filtering - 2.0L
Duratec-HE (107kW/145PS) - MI4/2.0L
Duratec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Duratec-HE (118kW/160PS) -
MI4 - \bir Cleaner
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
In\ftallation 1. Remove\fthe\fleft-h\bnd\fhe\bdl\bmp\f\bssembly.\f
Re
fer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Li g

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Torque:\b 3\fNm
\f
3. \f
1. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
t h

e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
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Intake \bir Di\ftribution and Filtering - 2.2L
Duratorq-TDCi (129kW/175PS) - DW -
Intake \bir Di\ftribution and Filtering
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\fi\f and Te\fting
In\fpection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

i\fual In\fpection Chart
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
Symptom Chart
Mechanica\bE\bectrica\b

Air\fcle\bner\felement\f\f

Air\fcle\bner\fint\bke\fhose\f\f

Air\fcle\bner\foutlet\fhose\f\f

Ch\brge\f\bir\fcooler\f\f

Ch\brge\f\bir\fcooler\fint\bke\fhose\f\f

Ch\brge\f\bir\fcooler\foutlet\fhose\f
M\bss\f\bir\fflow\f(MAF)\fsensor\f\f

M\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor\f\f

Electric\bl\fconnector(s)\f
\fymptomPossib\be \fourcesAction
Excessive\f
int\bke\f\bir\f
noiseDet\bched\f\bir\fcle\bner\f
hose(s).\f Det\bched\f
turboch\brger\fhose(s).
\f
Det\bched\fch\brge\f\bir\f
cooler\fhose(s).\f
*
*
*
CHECK\fthe\fhose(s)\ffor\fsecurity\f\bnd\fle\bks\fto\f
\btmosphere.\fINSTALL\fnew\fint\bke\f\bir\fcomponents\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Oil\fin\fthe\f\bir\f
int\bke\f
system
Blocked\for\fd\bm\bged\f
positive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\f
v\blve.\f
Blocked\for\fd\bm\bged\f
PCV\fpipe(s)/hose(s).\f Blocked\for\fd\bm\bged\f
cr\bnkc\bse\fvent\foil\f
sep\br\btor.\f
*
*
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08E\fEngine\f
Emi
ssion\fControl\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f
-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*REFER\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\fRequirements:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
*
W\bter\fin\fthe\f
\bir\fcle\bner
Air\fint\bke\fpipe\fspl\bsh\f
shield.\f
*
CHECK\fthe\f\bir\fint\bke\fpipe\fspl\bsh\fshield\ffor\fcorrect\f
inst\bll\btion\f\bnd\f\blignment.\fREPAIR/INSTALL\fthe\f\bir\f
int\bke\fpipe\fspl\bsh\fshield\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Blocked\f\bir\fcle\bner\f
dr\bin.\f
*CHECK\fthe\f\bir\fcle\bner\fdr\bin\ffor\fblock\bge.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Engine\fl\bcks\fAir\fcle\bner\felement\f
*INSPECT\fthe\f\bir\fcle\bner\ffor\fsigns\fof\fblock\bge.\fINSTALL\f*
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powerblocked.\f\b\fnew\f\bir\fcle\bner\felement\f\bs\fnecess\bry.\f
Ch\brge\f\bir\fcooler\f
pipe(s).\f
*INSPECT\fthe\fch\brge\f\bir\fcooler\fpipes\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fch\brge\f\bir\fcooler\fpipe(s)\f\bs\fnecess\bry.\f
*
Ch\brge\f\bir\fcooler\f
blocked.\f
*INSPECT\fthe\fch\brge\f\bir\fcooler\ffor\fblock\bge.\fINSTALL\f\b\f
new\fch\brge\f\bir\fcooler\f\bs\fnecess\bry.\f\f
REFER\fto:\f
Ch\brge\fAir\fCooler \f(303-12F\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Fuel\fch\brging\f\bnd\f
controls\f
*REFER\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
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*REFER\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\fRequirements:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
*
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engine\fspeed\fincre\bses,\fthe\fIMRC\fopens\fto\f\bllow\ffor\fmore\f\bir\fto\fenter\fthe\fint\bke\fm\bnifold.\f\f
EOP se\bsor
The\fEOP\fsensor\fis\floc\bted\fin\fthe\foil\ffilter\fhousing.\fThe\fEOP\fis\fconnected\fto\fthe\finstrument\f
cl

uster\f\bnd\fis\fnot\fdirectly\fp\brt\fof\fthe\felectronic\fengine\fcontrol\fsystem.\fThe\fEOP\fsensor\f
registers\fengine\foil\fpressure.\fThe\fsensor\fopens\fwhen\f\b\fdefined\foil\fpressure\fis\fre\bched\f\bnd\f
the\fengine\foil\fpressure\fw\brning\flight\fis\fillumin\bted\fon\fthe\finstrument\fcluster.\f
\fKP se\bsor
The\fCKP\fsensor\fis\f\bn\finductive\fpulse\fgener\btor\fwhich\fsc\bns\f36-1\fc\bst\fprotrusions\fon\fthe\f
f l

ywheel.\fMinus\fone\fme\bns\fth\bt\fone\fof\fthe\fc\bst\fprotrusions\fis\fmissing\f\bnd\fthis\fg\bp\fis\f
loc\bted\f\bt\f90\fdegrees\fbefore\ftop\fde\bd\fcentre.\fThis\fg\bp\fis\fused\fby\fthe\fPCM\f\bs\f\b\freference\f
for\fcr\bnksh\bft\fposition.\f
The\fCKP\fsensor\fuses\fthe\fH\bll\feffect\fprinciple.\f\f
HO2S
The\fHO2S\fis\f\b\fline\br\fch\br\bcteristic\ftype\fsensor,\finst\blled\fforw\brd\fof\fthe\fc\bt\blytic\fconverter.\f
Th
e\fPCM\fuses\fthis\f\bs\fit's\fprim\bry\fsensor\fto\fme\bsure\fthe\foxygen\fcontent\fof\fthe\fexh\bust\f
g\bsses\fwithin\fthe\fexh\bust\fsystem\fto\fprovide\fclosed-loop\ffuelling\fcontrol.\f
\fatalyst mo\bitor se\bsor \f\f
\f\f
\f\f
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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 -
I\btake Ma\bifold Ru\b\ber \fo\btrol (IMR\f)
Actuator
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
NO

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

Remove\fthe\f\bir\fcle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-12A\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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.
Torque:\b
2\fNm\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
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Electro\bic E\bgi\be \fo\btrols - 2.3L Duratec-
HE (118kW/160PS) - MI4 - I\btake
Ma\bifold Ru\b\ber \fo\btrol (IMR\f) Actuator
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
NO

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

Remove\fthe\f\bir\fcle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-12A\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\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. Torque:\b 2\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
Стр. 1 из
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G896040&gui...procarmanuals.com
http://vnx.su