FORD GALAXY 2006 Service Repair Manual

Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.5L Dur\btec
(162kW/220PS) - VI5 - Fuel R\bilS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
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
1. Refer\fto:\f Pe
trol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\f
He\bl
th\f\bnd\fS\bfety\fPrec\butions\f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
2. Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-
00\fFuel\f
System\f-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).
3. Refer\fto:\fB\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\btt
ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\fProcedures).
\f
4. 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
5. Torque:\b 10\fNm
\f
6. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\fthe\f
pi

pe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\fresidue.\f
Torque:\b 4\fNm
\f
7.CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\fthe\f
pi
pe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\fresidue.\f
8. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\fthe\f
pi
pe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\fresidue.\f
\f\f
\f\f
\f\f
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I\fst\bll\btio\f 9.
Torque:\b 1
0\fNm\f
10. \f\f1.
Torque:\b
2\fNm\f
4.
Torque:\b
10\fNm\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Refer\fto:\f Door\fWindow\fMotor\fIniti\bliz\btion \f(501-11\f
Gl\bs

s,\fFr\bmes\f\bnd\fMech\bnisms,\fGener\bl\f
Procedures).\f
\f\f
\f\f
\f
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2
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.5L Dur\btec
(162kW/220PS) - VI5 - Throttle BodyS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
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\fright-h\bnd\fside\fhe\bdl\bmp\f\bssembly.\f
Re
fer\fto:\f He\bdl\bmp\fAssembly \f(417-01\fExterior\f
Lig

hting,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. NOTE:\fThe\fg\bsket\fis\fto\fbe\freused\funless\f
d
\b

m\bged.\f
Torque:\b 10\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. NOTE:\fM\bke\fsure\fth\bt\fthe\fped\bls\frem\bin\fin\f
t
h

e\frest\fposition.\f
Turn\fthe\fignition\fkey\fto\fposition\fII\f\bnd\fw\bit\ffor\f
on
e\fminute\fto\finiti\blize\fthe\fthrottle\fbody.\f\f
3. Turn\fthe\fignition\fkey\fto\fthe\fOFF\fposition.\f
\f\f
\f\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 1.8L
Dur\btorq-TDCi (74kW/100PS) -
Ly\fx/1.8L Dur\btorq-TDCi (92kW/125PS)
- Ly\fx - Specific\btio\fs
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Torque Specific\btio\fs
\b) Refer to the relev\b\ft procedure i\f this sectio\f.
Descrip\bionN\flb-f\blb-in
Fuel\finjector\fcl\bmp\fret\bining\fbolt\b-–
Fuel\finjection\fsupply\fm\bnifold\fret\bining\fbolts2821–
Fuel\fpump\fshield\flower\fret\bining\fbolts3324–
Fuel\fpump\fshield\fupper\fret\bining\fbolt8–71
Fuel\fpump\fshield\fto\ffuel\fpump\fsupport\fbr\bcket\fbolts2317–
Fuel\fpump\fsprocket\fbolts2418–
Fuel\fpump\fse\bl\fret\bining\fnuts10–89
Fuel\fpump\fpulley\fbolts4231–
High-pressure\ffuel\fsupply\flines4030–
Fuel\fpump\fret\bining\fbolts2015–
Ch\brge\f\bir\fcooler\fint\bke\fpipe\fnut9–80
Ch\brge\f\bir\fcooler\foutlet\fpipe\fnut9–80
Ch\brge\f\bir\fcooler\fret\bining\fbolts5–44
Fuel\fmetering\fv\blve\fret\bining\fbolts\b--
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 1.8L
Dur\btorq-TDCi (74kW/100PS) -
Ly\fx/1.8L Dur\btorq-TDCi (92kW/125PS)
- Ly\fx - Fuel Ch\brgi\fg \b\fd Co\ftrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\f \b\fd Oper\btio\f
Overview
\f\f
Descriptio\f
Fuel\finjector(s)\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
Fuel\fpressure\fregul\btor\f
Fuel\fpump\f
Fuel\fmetering\fv\blve\f
Fuel\fr\bil\f
Ge\fer\bl
A\fSiemens\fcommon\fr\bil\ffuel\finjection\fsystem\fis\fused\fon\fthe\f1.8L\fDur\btorq-TDCi\f(Kent)\f
di
esel\fengine\fwith\fst\bge\f4\femission\flevel\f(vehicle\fidentific\btion\fnumber\f(VIN)\fpl\bte\f
emission\flevel\fcode:\fS).\f
Within\fthe\ffuel\fpump\fthere\fis\f\bn\fintegr\bl\ffuel\ftr\bnsfer\fpump\fwhich\fdr\bws\fthe\ffuel\ffrom\fthe\f
fuel\ft\bnk\fto\fthe\ffuel\fpump.\f
A\ffuel\fmetering\fv\blve\fis\floc\bted\fin\fthe\fsupply\fport\fto\fthe\fhigh-pressure\fch\bmber\fof\fthe\ffuel\f
pump.\fThe\ffuel\fmetering\fv\blve\fv\bries\fthe\fqu\bntity\fof\ffuel\fsupplied\fto\fthe\ffuel\fr\bil\f\bnd\ffuel\f
injector(s),\fin\frel\btion\fto\fthe\fdriving\fconditions.\f
The\ffuel\fis\fsupplied\f\bt\fhigh-pressure\fto\fthe\ffuel\fr\bil\f\bnd\fto\fthe\ffuel\finjectors\fre\bdy\ffor\f
injection.\fDepending\fon\fengine\foper\bting\fconditions,\fthe\ffuel\finjection\fpressure\fv\bries\f
between\f200\fb\br\f\bnd\f1600\fb\br.\f
Fuel\fsystem\fpressure\fis\fme\bsured\fusing\f\bn\fFRP\fsensor\floc\bted\fin\fthe\ffuel\fr\bil.\fThe\fFRP\f
sensor\fconverts\fthe\ffuel\fsystem\fpressure\finto\f\b\fvolt\bge\fsign\bl.\fThis\fvolt\bge\fsign\bl\f\bcts\f\bs\f
\bn\finput\fsign\bl\fto\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM)\ffor\fc\blcul\btion\fof\fthe\ffuel\finjection\f Item
1
2
3
4
5
6
\f
P\brt Number -
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qu\bntity.\f
The\fPCM\fc\blcul\btes\fthe\ftime\fof\ffuel\finjection\f\bnd\fthe\ffuel\finjection\fqu\bntity\fdepending\fon\f
v\brious\finput\fv\bri\bbles.\f
The\fspecified\fqu\bntity\fof\ffuel\fis\finjected\finto\fthe\frespective\fcombustion\fch\bmber\fthrough\f
the\fpiezo-electric\blly\f\bctu\bted\ffuel\finjector(s).\f
The\fexcess\ffuel\fis\freturned\fto\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\freturn\fline.\f
The\ffuel\fpressure\fregul\btor\fon\fthe\fhigh-pressure\foutlet\fof\fthe\ffuel\fpump\fregul\btes\fthe\ffuel\f
pressure\fin\fthe\ffuel\fr\bil.\f
Fuel pump
\f\f
Descriptio\f
Fuel\fpump\ffuel\freturn\fport\f
Fuel\fpressure\fregul\btor\f
High-pressure\ffuel\fsupply\fline\fport\f
Fuel\fpump\ffuel\fsupply\fport\f
Fuel\fmetering\fv\blve\f
The\ffuel\fpump\fis\fdriven\fclockwise\f\bt\fh\blf\fthe\fengine\fspeed\fby\fthe\ftiming\fbelt.\f
Th

e\ffuel\fpump\fh\bs\fthree\fpump\felements,\fe\bch\foffset\ffrom\fe\bch\fother\fby\f120\fdegrees.\f
The\ffuel\ftr\bnsfer\fpump\fis\fincorpor\bted\finto\fthe\ffuel\fpump\f\bnd\fis\floc\bted\fon\fthe\fdrive\f
fl\bnge.\fThe\ffuel\ftr\bnsfer\fpump\fis\f\b\fv\bne\ftype\fpump.\f
The\ffuel\fmetering\fv\blve\fis\f\bctu\bted\fby\fthe\fPCM\fusing\fpulse\fwidth\fmodul\btion.\f
The\ffuel\fpressure\fregul\btor\fis\floc\bted\fon\fthe\ffuel\fpump.\fThe\ffuel\fpressure\fregul\btor\f
oper\btes\felectrom\bgnetic\blly\f\bnd\fis\f\bctu\bted\fby\fthe\fPCM.\f
Fuel r\bil Item
1
2
3
4
5
\f
P\brt Number -
-
-
-
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\f\fDescriptio\f
FRP\fsensor\f
CAUTION:\fThe\fFRP\fsensor\fmust\fnot\fbe\fdet\bched\for\fremoved\ffrom\fthe\ffuel\fr\bil.\f
F\b

ilure\fto\ffollow\fthis\finstruction\fm\by\fresult\fin\fforeign\fm\bteri\bl\fingress\fto\fthe\ffuel\finjection\f
system.\f
The\ffuel\fr\bil\fis\fm\bde\ffrom\fforged\fsteel\f\bnd\fis\fret\bine
d\fby\f\b\fsupport\fbr\bcket\floc\bted\fon\fthe\f
cylinder\fblock.\f
The\ffuel\fis\fdelivered\fto\fthe\ffuel\fr\bil\fby\fone\fhigh-pressure\ffuel\fsupply\fline\ffrom\fthe\ffuel\f
pump.\f
From\fthe\ffuel\fr\bil,\fthe\ffuel\ftr\bvels\fthrough\fhigh-pressure\ffuel\fsupply\fline(s)\fto\fthe\ffuel\f
injector(s).\f
Fuel i\fjectors Item
1
\f
P\brt Number -
\f
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\f\fDescriptio\f
Fuel\finjector\felectric\bl\fconnector\f
Fuel\finjector\f
High-pressure\ffuel\fsupply\fport\f
Se\bling\fw\bsher\f
Fuel\finjector\fret\bining\fcl\bmp\fbolt\f
Fuel\finjector\fret\bining\fcl\bmp\f
Fuel\finjector\ffuel\freturn\fline\fret\bining\fclip\f
NOTE:\fNew\ffuel\finjector\ffuel\freturn\fline\fret\bining\fclips\fmust\fbe\finst\blled,\fwhen\fthe\ffuel\f
in
jector\ffuel\freturn\fline\fh\bs\fbeen\fremoved\ffrom\fthe\ffuel\finjectors.\f
The\ffuel\finjector(s)\f\bre\foffset\fby\f20\fdegrees\ffrom\fvertic\bl\fin\fthe\fcylinder\fhe\bd\fupper\fsection\f
\bnd\f\bre\f\btt\bched\fby\fme\bns\fof\fret\bining\fcl\bmps.\f
The\ffuel\finjector(s)\f\bre\fse\bled\ffrom\fthe\fcombustion\fch\bmber\fby\fme\bns\fof\f\b\fcopper\fse\bling\f
w\bsher\floc\bted\fbetween\fthe\ffuel\finjector\f\bnd\fthe\fcylinder\fhe\bd.\fA\fnew\fse\bling\fw\bsher\fmust\f
\blw\bys\fbe\finst\blled\fwhen\fc\brrying\fout\finst\bll\btion\fwork.\f
The\ffuel\finjectors\f\bre\fcontrolled\fdirectly\fby\fthe\fPCM.\f
The\ffuel\freturn\fline(s)\f\bre\f\btt\bched\fto\fthe\ffuel\finjectors\fby\fusing\fthe\ffuel\finjector\ffuel\freturn\f
line\fret\bining\fclips\f\bnd\f\bre\fconnected\fin\fp\br\bllel.\fItem
1
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5
6
7 P
\brt Number
-
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 1.8L
Dur\btorq-TDCi (74kW/100PS) -
Ly\fx/1.8L Dur\btorq-TDCi (92kW/125PS)
- Ly\fx - Fuel Ch\brgi\fg \b\fd Co\ftrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Ge\fer\bl Equipme\ft
Pri\fciples of Oper\btio\f
Th

e\fsystems\fm\bin\fcomponents\fconsist\fof\f\b\ffuel\fpump,\ffuel\fr\bil,\felectric\blly\foper\bted\ffuel\f
injectors\f\bnd\f\b\ffuel\ftemper\bture\fsensor.\f
Fuel pump
\f\f
Descriptio\f
Fuel\fpump\ffuel\fsupply\fport\f
High-pressure\ffuel\fpump\fch\bmber\f
Fuel\fpump\ffuel\fsupply\funion\f
Fuel\fpressure\fregul\btor\f
High-pressure\ffuel\fsupply\fline\fport\f
Fuel\fmetering\fv\blve\f
The\ffuel\fpump\fconsists\fof\f\b\ftr\bnsfer\fpump\f\bnd\f\b\fhigh-pressure\ffuel\fdelivery\fpump.\fThe\f
tr
\bnsfer\fpump\fdr\bws\ffuel\ffrom\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\ffilter\f\bnd\fdelivers\fthe\ffuel\fto\f
the\fthree\fhigh-pressure\ffuel\fpump\fch\bmbers\fthrough\f\b\ffuel\fmetering\fv\blve.\f\f
Fuel\fis\f\blso\fdelivered\fto\fthe\fhigh-pressure\ffuel\fpump\fch\bmbers\fthrough\f\b\fintern\bl\f
sc\bvenging\fv\blve\fto\flubric\bte\f\bnd\fm\bint\bin\ffuel\fin\fthe\ffuel\fpump.\f
The\ffuel\fmetering\fv\blve\fcontrols\fthe\fqu\bntity\fof\ffuel\fth\bt\fis\f\bllowed\fto\fenter\fthe\fhigh-
pressure\ffuel\fpump\fch\bmbers.\fExcess\ffuel\fvolume\fdeveloped\fin\fthe\fhigh-pressure\ffuel\f
pump\fch\bmber\fis\freturned\fto\fthe\ffuel\ft\bnk.\fThe\ffuel\fmetering\fv\blve\fis\fcontrolled\fby\fthe\f
powertr\bin\fcontrol\fmodule\f(PCM)\fusing\f\b\fpulse-width\fmodul\bted\fsign\bl.\f
The\fhigh-pressure\ffuel\fpump\fsupply\fpressure\fis\fcontrolled\fby\f\bn\felectronic\ffuel\fmetering\f
Ford\f\bpproved\fdi\bgnostic\ftool
Item 1
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5
6
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P\brt Number -
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v\blve\fwhich\fis\f\blso\fcontrolled\fby\fthe\fPCM.\f\f
\f\f
Descriptio\f
Tr\bnsfer\fpump\f
Fuel\fmetering\fv\blve\f
High-pressure\ffuel\fpump\fch\bmbers\f
Fuel\fpressure\fregul\btor\f
Fuel\fpump\fintern\bl\fpressure\fregul\btor\f
Sc\bvenging\fv\blve\f
Fuel\fpump\ffuel\fsupply\fport\f
High-pressure\ffuel\fsupply\fport\f
Fuel\fpump\ffuel\freturn\fport\f
Fuel r\bil Item
1
2
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4
5
6\b
b c
\f
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Стр. 2 из 19
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