engine FORD GALAXY 2006 Service Repair Manual

This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes\f\bnd\f
\blw\bys\fobserve\ffuel\fh\bndling\fprec\butions.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\fresult\fin\f
person\bl\finjury.\f
CAUTIONS:\f
Diesel\ffuel\finjection\fequipment\fis\fm\bnuf\bctured\fto\fvery\fprecise\ftoler\bnces\f\bnd\ffine\f
cle\br\bnces.\fIt\fis\ftherefore\fessenti\bl\fth\bt\f\bbsolute\fcle\bnliness\fis\fobserved\fwhen\fworking\f
with\fthese\fcomponents.\fAlw\bys\finst\bll\fbl\bnking\fplugs\fto\f\bny\fopen\forifices\for\flines.\f
Alw\bys\fc\brry\fout\fthe\fcle\bning\fprocess\fbefore\fc\brrying\fout\f\bny\frep\birs\fto\fthe\ffuel\f
injection\fsystem\fcomponents\fto\fprevent\fforeign\fm\btter\fingress\fto\fthe\fcomponents.\f
The\fgener\btor\fmust\fbe\fprotected\ffrom\fcont\bmin\btion.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\ff\bilure\fof\fthe\fgener\btor.\f
St\brt\fthe\fengine,\fw\bit\f\b\ffew\fminutes\f\bnd\fthen\f
observe\fthe\fcle\br\fpl\bstic\ffuel\fpipe\fin\fthe\ffuel\fpump\f
fuel\freturn\fline\ffor\fsigns\fof\f\bir\fingress.\f1
Are\f\bny\fsigns\fof\f\bir\fpresent\fin\fthe\fcle\br\fpl\bstic\ffuel\fpipe?\f
Ye\b GO\fto\fB2.\f\f
No F

or\f\bddition\bl\fdi\bgnostics\ffor\fFuel\fCh\brging\f\bnd\f
Controls,\f\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
B2: CHECK WHERE AIR IS ENTERIN\f THE SYSTEM
Using\fsuit\bble\fcle\bn\fengine\foil,\f\bpply\fthe\foil\fto\fe\bch\f
of\fthe\ffuel\fsupply\fline\f\bnd\ffuel\freturn\fline\f
connections,\funions\f\bnd\fjoints\fin\fturn\f\bnd\fobserve\f
the\fcle\br\fpl\bstic\fpipe\ffor\fvisible\fsigns\fof\f\bir\f\bfter\fe\bch\f
oil\f\bpplic\btion.\f
1
Did\fthe\f\bmount\fof\f\bir\fin\fthe\fcle\br\fpl\bstic\fpipe\fdecre\bse\f
when\f\bny\fof\fthe\fconnectors,\funions\for\fjoints\fwere\foiled?\f
Ye\b
INSTALL\f\b\fnew\ffuel\fpipe(s)\f\bs\fnecess\bry.\fTest\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No
\f\f
\f\f
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GO\fto\fB3.\f\f
B3: CHECK THE FUEL LEVEL SENSOR FOR AIR IN\fRESS
Dr\bin\fthe\ffuel\ft\bnk.\f\f
REFER\fto:\fFuel\fT\bnk\fDr\bining \f(310-00\fFuel\fSystem\f-
\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
1
Fill\fthe\ffuel\ft\bnk\fwith\f10\fliters\fof\fdiesel.\f2
Protect\fthe\fgener\btor\fwith\flint-free\fm\bteri\bl\fto\f
prevent\fcont\bmin\btion.\f3
Disconnect\fthe\ffuel\ffilter\ffuel\fsupply\fline\fquick\f
rele\bse\fcoupling.\f\f
REFER\fto:\f Spring\fLock\fCouplings \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).
\f
4
Using\f\b\fsuit\bble\fpiece\fof\fcle\br\fpl\bstic\fpipe,\f
m\bnuf\bcture\f\bnd\finst\bll\f\b\fpipe\fbetween\fthe\ffuel\ffilter\f
\bnd\fthe\ffuel\ft\bnk\fto\ffuel\ffilter\fsupply\fline.\f
5
Remove\fthe\flint-free\fm\bteri\bl.\f6
NOTE:\fM\bke\fsure\fth\bt\fthe\fengine\fis\f\bt\fnorm\bl\f
oper\bting\ftemper\bture.\f
St\brt\fthe\fengine,\fw\bit\f\b\ffew\fminutes\f\bnd\fthen\f
ob
serve\fthe\fcle\br\fpl\bstic\fpipe\ffor\fsigns\fof\f\bir\fingress.
\f
7
Are\f\bny\fsigns\fof\f\bir\fpresent\fin\fthe\fcle\br\fpl\bstic\fpipe?\f
Ye\b INSTALL\f\b\fnew\ffuel\flevel\fsensor\for\ffuel\ft\bnk\fto\ffuel\f
filter\fsupply\fpipe\f\bs\fnecess\bry.\f\f
No INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\fElement \f(310-01C\fFuel\fT\bnk\f
\bnd

\fLines\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
PINPOINT TEST C : FUEL FILTER FUEL SUPPLY LINE BLOCKA\fE -
VEHICLES WITH 1.8L DURATORQ-TDCI (KENT) DIESEL EN\fINE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
C1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKA\fE
WARNINGS:\f
Do\fnot\fsmoke\for\fc\brry\flighted\ftob\bcco\fof\f\bny\ftype\fwhen\fworking\fon\for\fne\br\f\bny\ffuel\f
rel\bted\fcomponents.\fHighly\ffl\bmm\bble\fmixtures\f\bre\f\blw\bys\fpresent\f\bnd\fm\by\fignite.\f
F\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes\f\bnd\f
\blw\bys\fobserve\ffuel\fh\bndling\fprec\butions.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\fresult\fin\f
person\bl\finjury.\f
\f\f
\f\f
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Fuel Sy\btem - \feneral Information -
Spring Lock Coupling\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
Special Tool(\b)
Mat

erial\b Di\bconnect
WARNINGS:\f
Re

fer\fto:\f Petrol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\fHe\blth\f\bnd\fS\bfe
ty\fPrec\butions\f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).\f
Refer\fto:\f Diesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fFuel\fsupply\fline\fconnectors\f\bre\fcolor\fcoded\fwhite.\fFuel\freturn\fline\fconnectors\f\bre\f
color\fcoded\fred.\f
310-040\f
Disconnect\fTool,\fFuel\fLine\f(5/16")\f
310-137\f
Disconnect\fTool,\fFuel\fLine\f
310-D004\f
Disconnect\fTool,\fSpring\fLock\fCoupling\f(3/8"\fyellow)
\f
310-D005\f
Disconnect\fTool,\fSpring\fLock\fCoupling\f(1/2"\fgreen)\f
412-038\f
Disconnect\fTool,\fSpring\fLock\fCoupling\f(5/8"\fbl\bck)\f
412-069\f
Disconnect\fTool,\fSpring\fLock\fCoupling\f(3/4"\fwhite)\f
NameSpec\bf\bcat\bo\f
Engine\fOil\f-\f5W-30WSS-M2C153-G
1. Rele\bse\fthe\ffuel\fsystem\fpressure\f
Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue

l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
2. Special\bTool(\f):\b 310-137\f
\f
\f
\f
\f
\f
\f
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Connect
7.
Special\bTool(\f):\b 3
10-D004,\f310-D005,\f412-038,\f
412-069\f
8. Sp

ecial\bTool(\f):\b 310-D004,\f310-D005,\f412-038,\f
412-069\f
9. \f
1

0. Special\bTool(\f):\b 310-D004,\f310-D005,\f412-038,\f
412-069\f
1. CAUTION:\fOnly\fuse\fthe\fspecified\f
m \b

teri\bl\fto\flubric\bte\fthe\fse\bls.\f
To\fconnect,\freverse\fthe\fdisconnect\fprocedure.\f
M at

erial:\b Engine\fOil\f-\f5W-30\f(WSS-M2C153-G) \f
\f\f
\f\f
\f\f
\f\f
\f\f
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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem Pre\b\bure Check—2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
Special Tool(\b)
\fen

eral Equipment WARNING:\fRefer\fto:\f Pet
rol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\fHe\blth\f\bnd\fS\bfe ty\f
Prec\butions \f(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btio
n).\f
Vehicles\fwith\f2.0L\fengine\f
310-025\f
Fuel\fPressure\fG\buge\f
310-025-18\f
Test\fHose\ffor\f310-025\f
310-025-19A\f
Test\fHose\ffor\f310-025\f
310-137\f
Disconnect\fTool,\fFuel\fLine
\f
Fl\bt-bl\bded\fscrewdriver
1. Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue
l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
2. General \bqui\fment: Fl\bt-bl\bded\fscrewdriver \f
\f
\f
\f
\f
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Vehicles\fwith\f2.3L\fengine\f
All\fvehicles\f
3.
General \bqui\fment: F
l\bt-bl\bded\fscrewdriver\f
4. S\f
ecial Tool(s): 310-137\f
5. In

stall the S\fecial Tool(s): 310-025,\f310-025-18
,\f
310-025-19A \f
6. In
stall the S\fecial Tool(s): 310-025-18\f
\f\f
\f
\f\f
\f\f
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7.Install the S\fecial Tool(s): 310-025-19A\f
8. S
t\brt\fthe\fengine\f\bnd\f\bllow\fit\fto\fidle.\f
9. Record\fthe\ffuel\fsystem\fpressure\f\bt\fidle\f(3.8\f+/-\f 0.2\fb\br\fm\bximum).\f
10. Stop\fthe\fengine.\f
11. Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fu e

l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
12. Remove the S\fecial Tool(s): 310-025-19A\f
13. R

emove the S\fecial Tool(s): 310-025-18\f
14 .

\f
\f\f
\f\f
\f\f
\f\f
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Vehicles\fwith\f2.0L\fengine\f
Vehicles\fwith\f2.3L\fengine\f
15. \f
16

. \f
\f\f
\f\f
\f\f
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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem Pre\b\bure Relea\beS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
Relea\be
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. Remove\fthe\ffuel\fpump\f\bnd\fsender\funit\ffuse.\f
3. St\brt\fthe\fengine\f\bnd\f\bllow\fit\fto\fidle\funtil\fthe\f engine\fst\blls.\f
4. Cr\bnk\fthe\fengine\ffor\f\bpproxim\btely\ffive\fseconds\f to\fm\bke\fsure\fth\bt\fthe\ffuel\fr\bil\fpressure\fis\f
rele\bsed.\f
5. Inst\bll\fthe\ffuel\fpump\f\bnd\fsender\funit\ffuse.\f
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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem Pre\b\bure Relea\be—2.0L EcoBoo\bt
SCTi (149kW/203PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
Pre\b\bure relea\be
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. \f
3. \f
4. St\brt\f\bnd\frun\fthe\fengine\f\bt\fidle\fspeed\funtil\fthe\f engine\fstops.\f
5. Cr\bnk\fthe\fengine\ffor\f\bpproxim\btely\f5\fseconds\fto\f rele\bse\fthe\ffuel\fpressure.\f
6. \f
7. \f
\f\f
\f\f
\f\f
\f\f
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