2006 FORD GALAXY fuel system

Engine\fknock\f
during\f\bcceler\btionFuel\finjector(s).\f
*REFER\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
M\bjor\fmech\bnic\bl\f
engine\ff\bilure.\f
*REFER\fto:\f
Engine\f(303-01C\fEngine\f-\f2.3L\f
Dur
\btec-HE\f(118kW/160PS)\f-\fMI4,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Fuel\fpressure\f
regul\btor.\f
*REFER\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Excessive\ffuel\f
consumption\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshing
DTC\fdetected.\f
*REFER\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
Excessive\ffuel\f
consumptionBr\bkes\fbinding.\f
*CHECK\fthe\fbr\bking\fsystem.\f\f
REFER\fto:\f Br\bke\fSystem\f(206-00\fBr\bke\fSystem\f
-\f Ge

ner\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
*
Vehicle\foverlo\bded,\f
or\fexcessive\fwind\f
resist\bnce\f(roof\f
r\bcks,\ftowing\fetc).\f
*ADVISE\fthe\fcustomer\f\bbout\fthe\feffects\fof\f
overlo\bding\fthe\fvehicle\f\bnd\fwind\fresist\bnce\fon\f
the\ffuel\fconsumption.\f
*
Air\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement.\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01A\fFuel\fT\bnk\f\bnd\f
Lin

es\f-\f2.0L\fEcoBoost\fSCTi\f(149kW/203PS)\f-\f
MI4/2.0L\fDur\btec-HE\f(107kW/145PS)\f-
\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Fuel\fsystem\fle\bk(s).\f
*CHECK\fthe\fsystem\ffor\ffuel\fle\bk(s).\fREPAIR\for\f
INSTALL\fnew\fp\brts\f\bs\fnecess\bry.\f
*
Du\bl\fm\bss\fflywheel.\f
*INSPECT\fthe\fdu\bl\fm\bss\fflywheel\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fdu\bl\fm\bss\fflywheel\f\bs\fnecess\bry.\f
*
Incorrect\fengine\foil.\f
*INSTALL\f\b\fnew\foil\ffilter\f\bnd\fengine\foil.\f
*
Gener\btor.\f
*REFER\fto\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08A\f
Eng
ine\fEmission\fControl\f-\f2.0L\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,\fDi\bgnosis\f\bnd\fTesting).\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\f
Fuel\fSystem\f-\f2.0L\fDur\btec-HE\f
(MI
4)/2.3L\fDur\btec-HE\f(MI4)/2.5L\fDur\btec\f(VI5)
\f
(310-00\fFuel\fSystem\f-\fGener\bl\fInform\btion,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\f
timing.\f
*CHECK\fthe\fv\blve\ftiming.\f\f
REFER\fto:\f Timing\fBelt \f(303-01E\fEngine\f-\f1.8L\f
Dur

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
Turboch\brger.\f
*REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-
TDCi\f(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fDi\bgnosis\f\bnd\fTesting).\f
*
Slipping\fclutch.\f\f
*REFER\fto:\f M\bnu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
Gener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
*
Low\fcylinder\f
compression.\f
*REFER\fto:\f
Engine\f(303-01C\fEngine\f-\f2.3L\f
Dur
\btec-HE\f(118kW/160PS)\f-\fMI4,\fDi\bgnosis\f
\bnd\fTesting).\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 - Fuel I\fjectio\f Compo\fe\ft
Cle\b\fi\fg
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Ge\fer\bl Procedures
M\bteri\bls
Ge\f

er\bl Equipme\ft CAUTION:\fUse\flint\ffree\fcloth.\f
NameSpec\bf\bcat\bo\f
Br\bke\fCle\bner3U7J-2C410-AA
Pneum\btic\fv\bcuum\fgun
1. Refer\fto:\f Solvents,\fSe\bl\bnts\f\bnd\fAdhesives \f(100-
00\f
Gener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\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. \f
3. CAUTION:\fUse\flint\ffree\fcloth.\f
Material\b Br
\bke\fCle\bner\f(3U7J-2C410-AA) \f
4. Using\f\b\fnew\fbrush\fth\bt\fwill\fnot\flose\fits\fbristles,\f
brush\f\b\fsuit\bble\fev\bpor\btive\fcle\bning\f\bgent\fonto\f
the\fcomponents\fbeing\fremoved\f\bnd\fonto\fthe\f
surrounding\f\bre\b.\f
5. Remove\f\bll\ftr\bces\fof\fev\bpor\btive\fcle\bning\f\bgent\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 - Fuel R\bil
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Ge\fer\bl Equipme\ft
Remov\bl
WAR

NINGS:\f
M\bk
e\fsure\fth\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\f
is\f\bt\f\bmbient\ftemper\bture.\f
W\bit\ffor\f\b\fminimum\fof\f1\fminute\f\bfter\fthe\fengine\fh\bs\fstopped\fbefore\fcommencing\f
\bny\frep\bir\fto\fthe\ffuel\finjection\fsystem.\f
Hose\fcl\bmp\fremover/inst\bller
1. 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. \f
3. CAUTION:\fUse\flint\ffree\fcloth.\f
Protect\fthe\fgener\btor\fto\fprevent\fcont\bmin\btion.\f\f
4. Cle\bn\fthe\ffuel\fpump,\ffuel\fr\bil,\fhigh-pressure\ffuel\f supply\fline\f\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(30

3-04E\fFuel\fCh\brging\f\bnd\fControls\f-\f2.0L\f
Dur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fGener\bl\fProcedures).\f
5. General \bqui\fment: Hose\fcl\bmp\f
rem

over/inst\bller \f
\f\f
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7. Remove\fthe\flint-free\fm\bteri\bl.\f
8. Refer\fto:\fFuel\fSystem\fBleeding\f-\f1.8L\fDur\btorq-
TDC

i\f(Lynx)\fDiesel \f(310-00\fFuel\fSystem\f-\f
Gen

er\bl\fInform\btion,\fGener\bl\fProcedures).\f
9. \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 - Fuel I\fjectors
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Ge\fer\bl Equipme\ft
Remov\bl
Fl\bt-bl\bded\fscrewdriver
Hose\fcl\bmp\fremover/inst\bller
Long\fnose\fpliers1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pr e

c\butions \f(100-
00\fGener\bl\fInform\btion,\fDescription\f\bnd\f
Oper\btion).\f
2. \f
3. General \bqui\fment: Hose\fcl\bmp\fremover/inst\bller \f
4. \f
5

. Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-
04E\f
Fuel\fCh\brging\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\f
Requirements:\fSt\bge\fIV,\fGener\bl\fProcedures).\f
6.
CAUTIONS:
Use\f\bn\f
open-ended\f
wrench\fto\f
\f\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 - Fuel Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Speci\bl Tool(s)
M\bt

eri\bls
Remov\bl
WA R

NINGS:\f
M\bk
e\fsure\fth\bt\fthe\ffuel\fpressure\fh\bs\fdropped\fto\fzero\f\bnd\fth\bt\fthe\ffuel\ftemper\bture\f
is\f\bt\f\bmbient\ftemper\bture.\f
W\bit\ffor\f\b\fminimum\fof\f1\fminute\f\bfter\fthe\fengine\fh\bs\fstopped\fbefore\fcommencing\f
\bny\frep\bir\fto\fthe\ffuel\finjection\fsystem.\f
205-072\f
Univers\bl\fFl\bnge\fHolding\fWrench\f
303-249\f
Remover,\fCr\bnksh\bft\fTiming\fPulley
\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fLBWSE-M4G323-A4\f/\f2U7J-M4G323-AA
Thre\bd\fLocking\fMSWSK-M2G349-A7\f/\f2U7J-M2G349-AA
1. 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. Remove\fthe\ftiming\fbelt.\f
Refer\fto:\f Timing\fBelt \f(303-01E\fEngine\f-\f1.8L\f
Du r

\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
3. CAUTION:\fUse\flint\ffree\fcloth.\f
Protect\fthe\fgener\btor\fto\fprevent\fcont\bmin\btion.\f\f
4. Cle\bn\fthe\ffuel\fpump,\ffuel\fr\bil,\fhigh-pressure\ffuel\f supply\fline\f\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f
(30

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
5. CAUTIONS:\f
M\b
ke\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
\f
\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.0L
Dur\btorq-TDCi (85kW/115PS) - DW/2.0L
Dur\btorq-TDCi (100kW/136PS) -
DW/2.0L Dur\btorq-TDCi (103kW/140PS)
- DW, Emissio\f Requireme\fts: St\bge IV -
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
Ge\fer\bl Overview
\f\f
Descriptio\f
Fuel\ffilter\fhousing\f
Fuel\finjector(s)\f
Fuel\fpump\f
Fuel\fmetering\fv\blve\f
Fuel\fpressure\fregul\btor\f
High-pressure\ffuel\fsupply\fline(s)\f
Fuel\fr\bil\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
Int\bke\f\bir\fshutoff\fthrottle\f
A\fSiemens\fcommon\fr\bil\fdiesel\finjection\fsystem\fis\fused\fon\fthe\f2.0L\fDur\btorq\fTDCi\f(DW10)\f Item
1
2
3
4
5
6
7
8
9
\f
P\brt Number -
-
-
-
-
-
-
-
-
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engine.\f
Within\fthe\ffuel\fpump\fis\f\bn\fintegr\bl\ffuel\ftr\bnsfer\fpump\fwhich\fdelivers\fthe\ffuel\ffrom\fthe\ffuel\f
t\bnk\fto\fthe\ffuel\fpump.\f
A\ffuel\fmetering\fv\blve\fis\floc\bted\fin\fthe\ffeed\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\fpump\f
elements,\fin\f\bccord\bnce\fwith\fdriving\fconditions.\f
At\fhigh-pressure,\fthe\ffuel\fis\fsent\fto\fthe\ffuel\fr\bil\f\bnd\fthen\fto\fthe\ffuel\finjectors\fre\bdy\ffor\ffuel\f
injection.\fDepending\fon\fengine\foper\bting\fconditions,\fthe\ffuel\finjection\fpressure\fv\bries\f
between\f\bpproxim\btely.\f350\fb\br\f\bnd\f1650\fb\br.\f
Fuel\fpressure\fis\fme\bsured\fusing\f\b\fFRP\fsensor\fon\fthe\ffuel\fr\bil.\fThe\fFRP\fsensor\fconverts\fthe\f
fuel\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\f
powertr\bin\fcontrol\fmodule\f(PCM)\ffor\fc\blcul\btion\fof\fthe\fcorrect\ffuel\finjection\fqu\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\finjectors.\fIn\fdoing\fso,\f\b\fpre-injection\f\bnd\f\b\fm\bin\f
injection\foccur\fe\bch\ftime.\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\f\bnd\fthereby\f\blso\fthe\fpressure\fwithin\fthe\ffuel\fr\bil.\f
Fuel pump
\f\f
Descriptio\f
High-pressure\foutlet\funion\f
Fuel\fpump\ffuel\fsupply\funion\f
Fuel\fmetering\fv\blve\f
Fuel\freturn\funion\f
Fuel\fpressure\fregul\btor\f
The\ffuel\fpump\fis\f\btt\bched\fto\fthe\fcylinder\fhe\bd\fon\fthe\ftr\bnsmission\fside\f\bnd\fis\fdriven\f
d i

rectly\fby\fthe\fexh\bust\fc\bmsh\bft\fthrough\f\b\fdrive\ffl\bnge.\f
Item
1
2
3
4
5
\f
P\brt Number -
-
-
-
-
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