fuel pressure FORD GALAXY 2006 Service Owner's Manual

Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) -
Lynx/\b.8L \furatorq-T\fCi (92kW/\b25PS) -
Lynx - Cylinder Head
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\f
Removal and Installation
Special Tool(s)
Mat
erials
General Equipment
Removal
WA R

NINGS:\f
This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes\f\bnd\f\blw\bys\f
observe\ffuel\fh\bndling\fprec\butions.\f\f
M\bke\fsure\fth\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\fis\f\bt\f
\bmbient\ftemper\bture.\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench
\f
303-122\f
Lifting\fBr\bcket,\fEngine\f
303-193\f
Timing\fPeg,\fCr\bnksh\bft\fTDC\f
303-376B\f
Alignment\fPl\bte,\fC\bmsh\bft\f
303-393\f
Locking\fTool,\fFlywheel\f
303-651\f
Remover,\fC\bmsh\bft\fSprocket\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C912-A1
Spoiler\fAdhesive\fKit\f2\fComponentWSK-M5B401-A1\f/\f2U7J-M2G376-AA
C\bble\fties
Dowel\fwith\f\b\fdi\bmeter\fof\f4\fmm
Trolley\fj\bck
1. Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-04D\f
Fuel\fCh\brging\f\bnd\fControls\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
\f
\f
\f
\f
\f
\f
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14. Remove\fthe\fFuel\fFilter.\fRefer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\fLines\f-
\f
1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
15. \f
16. NOTE:\fOnly\frot\bte\fthe\fc\bmsh\bft\fin\fthe\fnorm\bl\f
di

rection\fof\frot\btion.\f
Using\fthe\fc\bmsh\bft\fgroove\f\bs\f\b\fguide,\frot\bte\fthe\f
cr\bnksh\bft\fto\f5\fdegrees\fbefore\ftop\fde\bd\fcenter\f(TDC).\f
17. \f
18.
CAUTION:\fM\bke\fsure\fth\bt\fthe\f\bre\b\f\bround\fthe\f
component\fis\fcle\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
Refer\fto:\f Fu
el\fInjection\fComponent\fCle\bning\f(303-04D\f
Fuel\fCh\brging\f\bnd\fControls\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fGener\bl\fProcedures).\f
19. Disc\brd\fthe\fhigh-pressure\ffuel\fsupply\flines.\f
\f\f
\f\f
\f\f
\f\f
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injector\f\bnd\fthe\fblue\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\fr\bil.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\fwith\f
the\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\fto\fthe\ffuel\f
pump\f\bnd\fthe\fblue\fidentific\btion\fcoll\br\f\bdj\bcent\fto\f
the\ffuel\fr\bil.\f
NOTE:\fThe\fhigh-
pressure\ffuel\fsupply\flines\fmust\fbe\f
connected\fimmedi\btely\f\bfter\fremoving\fthe\fbl\bnking\f
plugs.\f
NOTE:\fDo\fnot\f\bllow\fthe\funions\fto\fhit\fthe\fends\fof\f
the\fhigh-pressure\ffuel\fsupply\fline.\fTo\f\bid\f
inst\bll\btion\fof\fthe\fnew\fhigh-pressure\ffuel\fsupply\f
lines,\fthe\funions\f\bt\fthe\ffuel\fr\bil\fend\f\bre\fcolored\f
gold.\f
Tighten\fthe\ffuel\finjector\fhigh-
pressure\ffuel\fsupply\flines\f
in\fthe\fsequence\fshown.\f
Torque: 1-5\f25\fNm
\f
6-10\f38\fNm
\f
thermost\bt\fhousing\f23\fNm
\f
v\bcuum\fpipe\f18\fNm
\f
35. Torque:
1\f7\fNm
\f
2\f23\fNm
\f
3\f23\fNm
\f
36. Inst\bll\fthe\fFuel\fFilter.\f Refer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\fLines\f-
\f
1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
37. Torque: 23\fNm
\f
38. \f\f 1.Torque: 3\fNm
\f
2. Torque: 5\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 5-
Speed Manual Transaxle
(MTX-75)
Removal
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2.
3. Remove \bhe a\fr cleaner. Refer \bo: A\fr Cleaner (303-
12D In\bake A\fr D\fs\br\fbu\b\fon and F\fl\ber\fng
Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
4. Remove \bhe ba\b\bery.
Refer \bo: Ba\b\bery (414-
01 Ba\b\bery, Moun\b\fng and Cables, Removal and Ins\balla\b\fon).
5.
6. Dra\fn \bhe cool\fng sys\bem.
Refer \bo:
Cool\fng Sys\bem Dra\fn\fng, F\fll\fng and Bleed\fng
Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, General Procedures).
7.



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Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 6-
Speed Manual Transaxle
(MMT6)
Removal
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2.
3. Remove \bhe a\fr cleaner. Refer \bo: A\fr Cleaner (303-
12D In\bake A\fr D\fs\br\fbu\b\fon and F\fl\ber\fng
Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
4. Remove \bhe ba\b\bery.
Refer \bo: Ba\b\bery (414-
01 Ba\b\bery, Moun\b\fng and Cables, Removal and Ins\balla\b\fon).
5.
6. Dra\fn \bhe cool\fng sys\bem.
Refer \bo:
Cool\fng Sys\bem Dra\fn\fng, F\fll\fng and Bleed\fng
Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, General Procedures).
7.



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14. Cle\bn\fthe\f\bre\b\f\bround\fthe\ffuel\finjection\fsupply\fm\bnifold,\fhigh\fpressure\ffuel\fsupply\flines\f\bnd\f
surrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(3 0

3-04D\fFuel\fCh\brging\f\bnd\fControls\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fGener\bl\f
Procedures).\f
15. CAUTIONS:\f
Us
e\f\bn\fopen-ended\fwrench\fto\fprevent\f
the\fcomponent\ffrom\fturning.\f
M\bke\fsure\fth\bt\fthe\ffuel\fline\frem\bins\fin\f
cont\bct\f\bt\fboth\fends\funtil\fboth\funions\fnuts\f
h\bve\fbeen\funscrewed\f\bnd\fthe\f\bre\b\f\bround\f
the\fjoints\fthoroughly\fcle\bned.\f
V\bcuum\f\bny\fforeign\fm\bteri\bl\ffrom\fthe\f
fuel\fpump\f\bnd\ffuel\fr\bil\funions\fbefore\fse\bling\f
the\funions\fwith\fbl\bnking\fc\bps.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f
16. \f
17. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\br

e\fse\bled.\fUse\fnew\fbl\bnking\fc\bps.\f
18. \f
\f\f
\f
\f\f
\f\f
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33. Disc\brd\fthe\ffuel\fpump\fse\bl\fret\biner.\f
34. \f
35. \f
36. Remove\fthe\fclutch\fdisc\f\bnd\fpressure\fpl\bte.\fRefer\fto:\f Clutch\fDisc\f\bnd\fPressure\fPl\bte \f(308-
01 B

\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl\f\bnd\fInst\bll\btion).\f
37. Disc\brd\fthe\fflywheel\fret\bining\fbolts.\f
Special\bTool(\f):\b 303-393\f
38.

\f
\f\f
\f\f
\f\f
\f\f
\f\f
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8. Remove\fthe\fFuel\fFilter.\fRefer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\f
Li n

es\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
9. NOTE:\fOnly\frot\bte\fthe\fc\bmsh\bft\fin\fthe\f
no

rm\bl\fdirection\fof\frot\btion.\f
Using\fthe\fc\bmsh\bft\fgroove\f\bs\f\b\fguide,\frot\bte\fthe\f
cr
\bnksh\bft\fto\f5\fdegrees\fbefore\ftop\fde\bd\fcenter\f
(TDC).\f\f
10. \f
11. Cle\bn\fthe\f\bre\b\f\bround\fthe\ffuel\finjection\fsupply\f m\bnifold,\fhigh\fpressure\ffuel\fsupply\flines\f\bnd\f
surrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(3 0

3-04D\fFuel\fCh\brging\f\bnd\fControls\f-\f1.8L\f
Dur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fGener\bl\f
Procedures).\f
12. CAUTIONS:\f
Us
e\f\bn\fopen-ended\fwrench\fto\fprevent\f
the\fcomponent\ffrom\fturning.\f
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\finjector\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
NOTE:\fThe\ffuel\fsupply\fline\fmust\fbe\finst\blled\f
\f\f
\f\f
\f\f
\f\f
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with\fthe\fyellow\fidentific\btion\fcoll\br\f\bdj\bcent\f
to\fthe\ffuel\fpump\f\bnd\fthe\fblue\fidentific\btion\f
coll\br\f\bdj\bcent\fto\fthe\ffuel\fr\bil.\f
Disc\brd\fthe\fhigh-pressure\ffuel\fsupply\flines.\f
13

. Disc\brd\fthe\fthermost\bt\fhousing\fg\bsket.\f
14. \f
15. Disc\brd\fthe\ffuel\finjector\fse\bling\fw\bshers.\f
16. \f
17. Disc\brd\fthe\fcr\bnksh\bft\fpulley\fret\bining\fbolt.\f Special\bTool(\f):\b 205-072\f
\f\f
\f\f
\f\f
\f\f
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51.CAUTION:\fUse\f\bn\fopen-ended\fwrench\f
to
\fprevent\fthe\fcomponent\ffrom\fturning.\f
NOTE:\fThe\fhigh-pressure\ffuel\fsupply\flines\f
must\fbe\fconnected\fimmedi\btely\f\bfter\f
removing\fthe\fbl\bnking\fplugs.\f
NOTE:\fDo\fnot\f\bllow\fthe\funions\fto\fhit\fthe\f
ends\fof\fthe\fhigh-pressure\ffuel\fsupply\fline.\f
To\f\bid\finst\bll\btion\fof\fthe\fnew\fhigh-pressure\f
fuel\fsupply\flines,\fthe\funions\f\bt\fthe\ffuel\fr\bil\f
end\f\bre\fcolored\fgold.\f
Tighten\fthe\finjector\fends\fin\fsequence\f
4,

3,2,1\f
Tor\fue\b 25\fNm
\f

Tighten\fthe\ffuel\fpump\fend\f5\f
To

r\fue\b 25\fNm
\f

Tighten\fr\bil\fend\fin\fsequence\f1,2,3,4,5\f
To

r\fue\b 38\fNm
\f

Inst\bll\f\b\fnew\fthermost\bt\fhousing\fg\bsket.\f
To

r\fue\b thermost\bt\fhousing\f23\fNm
\f
v\bcuum\fpipe\f18\fNm
\f
52. Tor\fue\b
1\f7\fNm
\f
2\f23\fNm
\f
3\f23\fNm
\f
53. Inst\bll\fthe\fFuel\fFilter.\f Refer\fto:\f Fuel\fFilter \f(310-01B\fFuel\fT\bnk\f\bnd\f
Lin

es\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
54. Tor\fue\b 23\fNm
\f
\f\f
\f\f
\f\f
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