FORD S-MAX 2006 Service Repair Manual

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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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem Bleeding—2.0L Duratorq-TDCi
(DW) Die\bel
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
Special Tool(\b)
310-025-19A\f
Test\fHose\ffor\f310-025\f
310-042\f
Connector\ffor\f310-025\f
310-110A\f
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit
\f
1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Prec\butions\f(100-00,\fDescription\f\bnd\fOper\btion).
\f
2. \f
3.Special\b
Tool(\f):\b
310-025-
19A ,

\f310-
110

A ,\f
310-042 \f
\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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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem Bleeding—2.2L Duratorq-TDCi
(DW) Die\bel
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
Special Tool(\b)
310-110A\f
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit
\f
1. \f
2. WARNING:\fBe\fprep\bred\fto\fcollect\f
es

c\bping\ffuel.\f
CAUTION:\fExtreme\fcle\bnliness\fmust\fbe\f
exercised\fwhen\fh\bndling\fthese\fcomponents.\f
3. WARNING:\fBe\fprep\bred\fto\fcollect\f
es
c\bping\ffuel.\f
Oper\bte\fthe\fh\bnd\fpressure\fpump\fspeci\bl\ftool\f
\bd\bp
ter\funtil\fthe\ffuel\ffilter\fis\ffull\f\bnd\fthe\fspeci\bl\f
tool\fbecomes\ffirm.\f
Special\bTool(\f):\b 310-110A\f
4. \f
\f
\f\f
\f\f
\f\f
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5.Torque:\b 10\fNm\f
\f\f
\f\f
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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
a\bd L\f\bes—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
Descr\fpt\fo\b a\bd Operat\fo\b
Ge\beral overv\few
\f\f
Descr\fpt\fo\b
Fuel\fr\bil\f
Fuel\fsupply\fline\f
Ev\bpor\btive\femission\fc\bnister\fto\fev\bpor\btive\femission\fc\bnister\fpurge\f
v\blve\fline\f
Ev\bpor\btive\femission\fc\bnister\fpurge\fv\blve\f
Ev\bpor\btive\femission\fc\bnister\fpurge\fto\fint\bke\fm\bnifold\fv\bcuum\fline\f
Int\bke\fm\bnifold\f
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Part Number -
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\f\fDescr\fpt\fo\b
Fuel\ft\bnk\ffiller\fpipe\f
Fuel\ft\bnk\ffiller\fpipe\fc\bp\f
Fill\flimit\fvent\fv\blve\f
Ev\bpor\btive\femission\fc\bnister\f
Ev\bpor\btive\femission\fc\bnister\fdust\ffilter\f
Fuel\ft\bnk\fsupport\fstr\bps\f
Fuel\ft\bnk\fvent\fv\blve(s)\f
Fuel\fpump\f\bnd\fsender\funit\f(including\ffuel\ffilter)\f
Fuel\fsupply\fline\f
Ev\bpor\btive\femission\fc\bnister\fto\fev\bpor\btive\femission\fc\bnister\fpurge\f
v\blve\fline\f
Fuel\ft\bnk\f
The\ffuel\ft\bnk\fholds\f\bpproxim\btely\f70\fliters\fof\fus\bble\ffuel\f\bnd\fis\fof\f\b\fpl\bstic\fconstruction.\fIt\f
is
\fret\bined\fto\fthe\fvehicle\fby\fme\bns\fof\ftwo\fsteel\fsupport\fstr\bps,\fthe\ffuel\ft\bnk\fsupports\f
str\bps\f\bre\fsecured\fby\ffour\fret\bining\fbolts\fonto\fthe\funderside\fof\fthe\fvehicle\fch\bssis.\f
Fuel\ft\bnk\fventil\btion\fis\f\bchieved\fby\ftwo\ffuel\ft\bnk\fvent\fv\blves\fventing\fthrough\f\b\ffuel\flimit\f
vent\fv\blve\f\bnd\finto\f\bn\fev\bpor\btive\femission\fc\bnister\fwhich\f\bbsorbs\fthe\ffuel\fv\bpor.\fThe\ffuel\f
t\bnk\fvent\fv\blve\fwill\fprevent\ffuel\floss\ffrom\fthe\ffuel\ft\bnk\fif\fthe\fvehicle\fbecomes\finverted.\f\f
Fuel l\f\bes Item
1
2
3
4
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6
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9
10
1

1
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Part Number -
-
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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
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Part Number -
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\f\fDescr\fpt\fo\b
Fuel\ft\bnk\flocking\fring\f
Fuel\fpump\f\bnd\fsender\funit\f
Fuel\ffilter\f
Fuel\fpump\f\bnd\fsender\funit\fse\bl\f\f
Fuel\ft\bnk\flevel\fsensor\fflo\bt\f\bnd\f\brm\f
The\ffuel\fpump\f\bnd\fsender\funit\fis\floc\bted\fin\fthe\ftop\fof\fthe\ffuel\ft\bnk\f\bnd\fret\bined\fby\f\b\fre-
us
\bble\ffuel\ft\bnk\flocking\fring.\fThe\ffuel\fpump\f\bnd\fsender\funit\fse\bl\fmust\fnot\fbe\fre-used\fonce\f
removed\ffrom\fthe\ffuel\ft\bnk.\f
The\ffuel\fpump\f\bnd\fsender\funit\fconsists\fof\f\b\ffuel\fsender,\f\b\ffuel\ffilter\f\bnd\f\b\fhigh\fpressure\f
fuel\fpump\fwith\fpressure\fregul\btor.\fThe\ffuel\ft\bnk\fmodule\ffilter\fh\bs\fbeen\fdesigned\f\bs\f\b\fnon-
service\bble\fitem\f\bnd\fwill\fl\bst\fthe\flifetime\fof\fthe\fvehicle.\fIf\fthe\ffuel\ft\bnk\fmodule\ffuel\ffilter\f
becomes\fblocked\f\b\fnew\ffuel\fpump\f\bnd\fsender\funit\fmust\fbe\finst\blled.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f Fuel\fPump\f\bnd\fSender\fUnit\f(310-01A\fFuel\fT\bnk\f\bnd\f
Li n

es\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\fMI4/2.0L\fDur\btec-HE\f(107kW/145PS)\f-\f
MI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\f
MI4/2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
The\ffuel\fpump\fis\f\b\fturbine\ftype\fpump\fwhich\fis\f\bn\fintegr\bl\fp\brt\fof\fthe\ffuel\fpump\f\bnd\fsender\f
unit.\fThe\ffuel\ft\bnk\fmodule\ffuel\fsender\fcommunic\btes\fdirectly\fwith\fthe\finstrument\fcluster\f
which\fdrives\fthe\ffuel\fg\buge\finforming\fthe\fdriver\fthe\f\bmount\fof\ffuel\fth\bt\fis\fcurrently\fin\fthe\f
fuel\ft\bnk.\f
CAUTION:\fT\bke\fextr\b\fc\bre\fnot\fto\fd\bm\bge\fthe\ffuel\ft\bnk\f l
evel\fsensor\fflo\bt\f\bnd\f\brm.\f
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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 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
\f\f
Descr\fpt\fo\b
Fill\flimit\fvent\fv\blve\f
The\ffill\flimit\fvent\fv\blve\fis\f\bn\fintermedi\bte\fventil\btion\fv\blve\fbetween\fthe\ffuel\ft\bnk\fvent\f
v\b
lves\f\bnd\fthe\fev\bpor\btive\femission\fc\bnister.\f
The\ffill\flimit\fvent\fv\blve\f\bllows\fthe\ffuel\ft\bnk\fto\fbe\ffilled\fto\fits\fm\bximum,\fby\fexpelling\fthe\f\bir\f
within\fthe\ffuel\ft\bnk\fto\fthe\fev\bpor\btive\femission\fc\bnister.\f
Evaporat\fve em\fss\fo\b system
The\fev\bpor\btive\femission\fsystem\fconsists\fof\f\bn\fev\bpor\btive\femission\fc\bnister,\fev\bpor\btive\f
emission\fc\bnister\fpurge\fv\blve\f\bnd\fv\bcuum\flines.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f Ev\bpor\btive\fEmissions\f(303-13\fEv\bpor\btive\fEmissions,\f
De s

cription\f\bnd\fOper\btion).\f
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