engine FORD GALAXY 2006 Service Repair Manual

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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4. Refer\fto:\fQuick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
5. CAUTION:\fThe\fst\brter\fmotor\foper\btion\f
m u

st\fnot\fexceed\f10\fseconds\f\bt\f\b\ftime.\fAfter\f
10\fseconds\fturn\fthe\fignition\fswitch\fto\f
position\f0\f\bnd\f\bllow\fthe\fst\brter\fmotor\fto\fcool\f
for\f30\fseconds\fbefore\foper\bting\fthe\fst\brter\f
motor\f\bg\bin.\f St\brt\fthe\fengine\f\bnd\f\bllow\fit\fto\fidle\funtil\fit\f
re
\bches\fnorm\bl\foper\bting\ftemper\bture.\f
6. Switch\foff\fthe\fengine.\f
7. Remove t\be Spe\fial Tool(s): 310-110A,\f310-
110

A-01 \f
\f\f
\f\f
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4. Oper\bte\fthe\fh\bnd\fpressure\fpump\fspeci\bl\ftool\f\bd\bpter\funtil\ffuel\fis\fvisible\fin\fthe\fcle\br\fpl\bstic\f
tube.\f
Special\bTool(\f):\b 310-025-19A,\f310-110A ,\f310-
042 \f
5

. CAUTION:\fThe\fst\brter\fmotor\foper\btion\f
mu

st\fnot\fexceed\f10\fseconds\f\bt\f\b\ftime.\fAfter\f
10\fseconds\fturn\fthe\fignition\fswitch\fto\f
position\f0\f\bnd\f\bllow\fthe\fst\brter\fmotor\fto\fcool\f
for\f30\fseconds\fbefore\foper\bting\fthe\fst\brter\f
motor\f\bg\bin.\f St\brt\fthe\fengine\f\bnd\f\bllow\fit\fto\fidle\funtil\fit\f
r e

\bches\fnorm\bl\foper\bting\ftemper\bture.\f\f
6. Switch\foff\fthe\fengine.\f
7. Remove\bthe\bSpecial\bTool(\f):\b 310-025-19A,\f310-
025

-19A ,\f310-110A \f
8. \f
\f
\f\f
\f\f
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\f\fDescr\fpt\fo\b
Fuel\fline\fcover\f
Fuel\fsupply\fline\f
Ev\bpor\btive\femission\fc\bnister\fto\fev\bpor\btive\femission\fc\bnister\fpurge\f
v\blve\fline\f
The\ffuel\fsupply\f\bnd\freturn\flines\f\bre\fconstructed\ffrom\fPA\fnylon\ftubes\f\bnd\f\bre\fret\bined\fby\f
cl
ips\fwhich\f\bre\fm\bde\fof\fpl\bstic.\fThe\ffuel\flines\f\bre\fprotected\funder\fthe\fvehicle\fby\f\b\fpl\bstic\f
cover,\fwhich\fis\fclipped\fto\fwelded\fstuds.\f
Within\fthe\fengine\fcomp\brtment,\fsome\ffuel\flines\f\bre\fproduced\ffrom\fsteel\ffor\fimproved\f
robustness.\f
The\ffuel\fsupply\f\bnd\freturn\flines\f\bre\fsep\br\bted\finto\fthree\fsections.\fThe\ffuel\fline\fconnections\f
h\bve\fquick\frele\bse\fcouplings\f\bt\fe\bch\fend\fto\fsecure\fthem\fto\fthe\ffuel\ft\bnk\flines\f\bnd\ffront\fend\f
fuel\flines.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f Quick\fRele\bse\fCoupling\f(310-00\fFuel\fSystem\f-\fGener\bl\f
Inf

orm\btion,\fGener\bl\fProcedures).\f
Fuel pump a\bd se\bder u\b\ft Item
1
2
3
\f
Part Number -
-
-
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Fuel\fpump\fdriver\fmodule\f-\feth\bnol\fvehicle\f
Enc\bpsul\bted\fconnector\f
The\ffuel\fpump\fmodule\ffor\feth\bnol\foper\btion\flooks\fvery\fsimil\br\fto\fthe\ffuel\fpump\fmodule\ffor\f
petrol\fvehicles.\fThe\fdifference\fis\fin\fthe\ffuel\fpump\fconnector.\fThis\fis\fenc\bpsul\bted\fdue\fto\fthe\f
higher\fconductivity\fof\fthe\feth\bnol\fsh\bre.\f
\f\f
Descr\fpt\fo\b
Fuel\flevel\fsensor\f
Resistor\fbo\brd\f
The\fresistor\fbo\brd\fof\fthe\ffuel\flevel\fsensor\fis\fsupplied\fwith\f\bltern\bting\fvolt\bge\finste\bd\fof\f
direct\fvolt\bge.\fThis\fprevents\felectrolysis\f\bnd\fthe\fdeposit\fof\fp\brticles.\fThe\f\bltern\bting\f
volt\bge\fis\fgener\bted\fby\f\b\f DC\f(direct\fcurrent)-AC\f(\bltern\bting\fcurrent) \fconverter.\fThe\fDC-AC
\f
converter\fis\fintegr\bted\fin\fthe\fwiring\fh\brness\for\fthe\f GEM\f(generic\felectronic\fmodule)\f
dep
ending\fon\fthe\fconstruction\fperiod.\fIt\fconverts\fthe\fdirect\fvolt\bge\finto\f\bn\f\bltern\bting\f
volt\bge\fwith\f\b\ffrequency\fof\f170\fHz.\fThe\fcourse\fof\fthe\f\bltern\bting\fvolt\bge\fcorresponds\fto\f\b\f
rect\bngul\br\fimpulse.\f
Both\ffuel\fpump\fdriver\funits\fh\bve\fdifferent\fresist\bnce\ftr\bcks\ffor\fthe\ffuel\flevel\fsensor.\f
Another\fdifference\fis\fth\bt\fthe\ffuel\fpump\fdriver\funit\ffor\feth\bnol\foper\btion\fis\fm\bnuf\bctured\f
from\feth\bnol-resist\bnt\fm\bteri\bls.\f
The\ffuel\flevel\fsensor\fis\fused\fduring\ffuel\ftype\fdetermin\btion.\f\f
Refer\fto:\f Electronic\fEngine\fControls\f-\fVehicles\fWith:\fEth\bnol\fC \b
p\bbility\f(303-14A\fElectronic\f
Eng
ine\fControls\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4,\fDescription\f\bnd\fOper\btion).\f 2
3
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em
1
2 \f\f
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Fuel l\f\bes
\f\f
Descr\fpt\fo\b
Fuel\fline\fcover\f
Fuel\fsupply\fline\f
Ev\bpor\btive\femission\fc\bnister\fto\fev\bpor\btive\femission\fc\bnister\fpurge\f
v\blve\fline\f
The\ffuel\fsupply\f\bnd\freturn\flines\f\bre\fconstructed\ffrom\fPA\fnylon\ftubes\f\bnd\f\bre\fret\bined\fby\f
cl
ips\fwhich\f\bre\fm\bde\fof\fpl\bstic.\fThe\ffuel\flines\f\bre\fprotected\funder\fthe\fvehicle\fby\f\b\fpl\bstic\f
cover,\fwhich\fis\fclipped\fto\fwelded\fstuds.\f
Within\fthe\fengine\fcomp\brtment,\fsome\ffuel\flines\f\bre\fproduced\ffrom\fsteel\ffor\fimproved\f
robustness.\f
The\ffuel\fsupply\f\bnd\freturn\flines\f\bre\fsep\br\bted\finto\fthree\fsections.\fThe\ffuel\fline\fconnections\f
h\bve\fquick\frele\bse\fcouplings\f\bt\fe\bch\fend\fto\fsecure\fthem\fto\fthe\ffuel\ft\bnk\flines\f\bnd\ffront\fend\f
fuel\flines.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f Quick\fRele\bse\fCoupling\f(310-00\fFuel\fSystem\f-\fGener\bl\f
Inf

orm\btion,\fGener\bl\fProcedures).\f
Fuel pump a\bd se\bder u\b\ft Item
1
2
3
\f
Part Number -
-
-
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NOTE:\fM\bke\fsure\fth\bt\fthe\finst\bll\btion\fm\brks\f\bre\f\bligned.\f
The\ffuel\ft\bnk\fmust\fbe\fcompletely\fremoved\ffrom\fthe\fvehi
cle\fbefore\fthe\ffuel\fpump\f\bnd\f
sender\funit\funit\fc\bn\fbe\fremoved.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f Fuel\fT\bnk\f(310-01A\fFuel\fT\bnk\f\bnd\fLines\f-\f2.0L\f
Eco

Boost\fSCTi\f(149kW/203PS)\f-\fMI4/2.0L\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-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Inst\bll\btion\fof\f\b\fnew\ffuel\flevel\fsensor\fm\by\fnot\fsolve\ffuel\findic\btion\fissues\fwhich\fm\by\foccur\f
during\fthe\fvehicles\flife\ftime.\f
Fuel pump dr\fver module (FPDM)
\f\f
Descr\fpt\fo\b
FPDM\f
The\fFPDM\freceives\fd\bt\b\ffrom\fthe\fPCM\freg\brding\fengine\foper\bting\fst\btes,\fwhich\fis\fthe\f
tr
\bnsferred\fto\fthe\ffuel\fpump\f\bnd\fsender\funit\fto\fdeliver\fthe\frequired\fqu\bntity\fof\ffuel\fto\fthe\f
fuel\fr\bil\fin\frel\btion\fto\fthe\fengine\fspeed\f\bnd\foper\bting\fconditions.\f
Fuel ta\bk ve\bt valve
\f\f
Descr\fpt\fo\b
Fuel\ft\bnk\fvent\fv\blve\f
Fuel\ft\bnk\fventil\btion\fis\f\bchieved\fby\ftwo\ffuel\ft\bnk\fvent\fv\blves\f\bnd\fthe\ffill\flimit\fvent\fv\blve,\f
wh
ich\f\bre\finst\blled\finto\fthe\ftop\fof\fthe\ffuel\ft\bnk\f\bnd\fwill\fprevent\ffuel\floss\ffrom\fthe\ffuel\ft\bnk\f
if\fthe\fvehicle\fbecomes\finverted.\f
The\ffuel\ft\bnk\fvent\fv\blve\f\blso\f\bcts\f\bs\f\b\ffuel\ft\bnk\fbre\bther\fwith\f\b\fdust\ffilter\floc\bted\f\bt\fthe\f
\btmospheric\fport\fof\fthe\fev\bpor\btive\femission\fc\bnister.\fIf\fthis\fdust\ffilter\fbecomes\fblocked\for\f
restricted\fduring\fthe\fvehicle's\flifetime,\fproblems\fwill\fbe\fexperienced\fwith\fdr\bining\fthe\ffuel\f
t\bnk.\fAlso\fthere\fcould\fbe\f\b\fpossibility\fof\ffuel\ft\bnk\fdeform\btion\fif\fthe\ffuel\ffilter\fis\fblocked.\f
F\fll l\fm\ft ve\bt valve Item
1
I t

em
1 \f\fPart Number
-
\f\f
Part Number-
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Fuel Ta\bk a\bd L\f\bes - 2.0L EcoBoost SCT\f
(149kW/203PS) - MI4/2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4/2.5L
Duratec (162kW/220PS) - VI5 - Fuel Ta\bk
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallat\fo\b
Spec\fal Tool(s)
Ge\b

eral Equ\fpme\bt
Removal All\fvehicles\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
Vehicles\fwith\f2.5L\fengine\f
310-069\f
Wrench,\fFuel\fT\bnk\fSender\fUnit
\f
Fuel\ft\bnk\fdr\bining\fequipment
Hose\fcl\bmp(s)
Hose\fcl\bmp\fremover/inst\bller
Ret\bining\fStr\bp
Tr\bnsmission\fj\bck
Wooden\fBlock1. Refer\fto:\fPetrol\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
Refer\fto:\f Diesel\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 Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
De s

cription\f\bnd\fOper\btion).\f
3. Torque:\b 10\fNm
\f
\f
\f
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All\fexcept\fvehicles\fwith\fdiesel\fengine\f
Vehicles\fwith\f2.0L\fdiesel\fengine\f
Vehicles\fwith\fdiesel\fengine\fNOTE:\fM\bke\fsure\fth\bt\fthe\fcl\bmp\fis\finst\blled\f
t
o

\fthe\fs\bme\forient\btion\f\bs\fwhen\fremoved.\f
Genera\f\bEquipment:\b Ho
se\fcl\bmp(s)\f
8. WARNING:\fBe\fprep\bred\fto\fcollect\f
es

c\bping\ffluid.\f
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
inst\blled.\f Genera\f\bEquipment:\b Ho
se\fcl\bmp\f
rem
over/inst\bller \f
9.WARNING:\fBe\fprep\bred\fto\fcollect\f
es
c\bping\ffluid.\f 1. Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\f
Fue
l\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
2. If\fequipped.\f
10. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
11. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Vehicles\fwith\ffuel\ffired\fbooster\fhe\bter\f
Vehicles\fwith\fdiesel\fengine\f
All\fexcept\fvehicles\fwith\fdiesel\fengine\f
All\fvehicles\fGenera\f\bEquipment:\b
Wo
oden\fBlock\f
18.
\f
19. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
20. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
21. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
\f\f
\f\f
\f\f
\f\f
\f\f
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