2006 FORD GALAXY fuel system

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 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
\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 R\bil
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
WARNING:\fM\bke\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
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
1. Refer\fto:\fDiesel\fFuel\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions
(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
2. Remove\fthe\fint\bke\fm\bnifold.\fRefer\fto:\f Int\bke\fM\bnifold\f(303-01F\fEngine\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
DW,\fEmission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Remove\fthe\ffuel\ffilter.\f
Refer\fto:\f Fuel\fFilter \f(310-01C\fFuel\fT\bnk\f\bnd\fLines\f-
\f2.0L\f
Dur\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
DW,\fEmission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. Torque:\b 9\fNm
\f
5. V\bcuum\fforeign\fm\bteri\bl\ffrom\fthe\fhigh-
pressure\ffuel\fsupply\f
line\funions\f\bnd\fcomponent\fthre\bds.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-
04E\fFuel\f
Ch\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\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,\fGener\bl\fProcedures).\f
6. \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 I\fjectors
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Speci\bl Tool(s)
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
303-174\f
G\buge,\fBolt\fAngle\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\fPrec\butions
(100-00\fGener\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
2. Remove\fthe\fint\bke\fm\bnifold.\f
Refer\fto:\f Int\bke\fM\bnifold\f(303-01F\fEngine\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Cle\bn\fthe\ffuel\finjectors,\ffuel\fr\bil,\fhigh-pressure\ffuel\fsupply\flines\f
\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\fFuel\fInjection\fComponent\fCle\bning\f(303-
04E\fFuel\f
Ch\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq
TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Gener\bl\fProcedures).\f
4. \f
\f
\f
Стр. 1 из 6
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7. \f
8.CAUTION:\fUse\flint\ffree\fcloth.\f
Protect\fthe\fgener\btor\fto\fprevent\fcont\bmin\btion.\f\f
9. Inst\bll\fthe\fint\bke\fm\bnifold.\f
Refer\fto:\f Int\bke\fM\bnifold\f(303-01F\fEngine\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
10. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\fSystem\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
11. Special\bTool(\f):\b 310-110A\f
\f
\f\f
\f\f
Стр. 5 из 6
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12. Oper\bte\fthe\fh\bnd\fpressure\fpump\f\bt\fle\bst\f30\ftimes.\f
13.
CAUTION:\fThe\fst\brter\fmotor\foper\btion\fmust\fnot\f
exceed\f10\fseconds\f\bt\f\b\ftime.\fAfter\f10\fseconds\fturn\fthe\f
ignition\fswitch\fto\fposition\f0\f\bnd\f\bllow\fthe\fst\brter\fmotor\fto\f
cool\ffor\f30\fseconds\fbefore\foper\bting\fthe\fst\brter\fmotor\f
\bg\bin.\f
St\brt\fthe\fengine\f\bnd\f\bllow\fto\fidle\funtil\fit\fre\bches\fnorm\bl\f
oper\bting\ftemper\bture\f
14. Stop\fthe\fengine.\f
15.Special\bTool(\f):\b 310-110A\f
16.

Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-
00\fFuel\fSystem\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
17. Remove\fthe\flint-free\fm\bteri\bl.\f
18. Torque:\b 9\fNm
\f
\f\f
\f\f
\f\f
\f\f
Стр. 6 из
6
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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 Pump
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl WAR
NING:\fRefer\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:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
1.Remove\fthe\fexh\bust\fm\bnifold\fto\fexh\bust\fg\bs\frecircul\btion\f
(EGR)\fv\blve\ftube.\f
Refer\fto:\f
Exh\bust\fM\bnifold\fto\fExh\bust\fG\bs\fRecircul\btion\f(EGR)\f
V\blve\fTube \f(303-08D\fEngine\fEmission\fControl\f-\f2.0L\f
Dur\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
DW,\fEmission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Remove\fthe\f\bir\fcle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-
12E\fInt\bke\fAir\fDistribution\f\bnd\f
Filtering\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
(103kW/140PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(118kW/160PS)\f
DW,\fEmission\fRequirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f
4. Cle\bn\fthe\ffuel\fpump,\ffuel\fr\bil,\fhigh-
pressure\ffuel\fsupply\fline\f
\bnd\fsurrounding\f\bre\bs.\f
Refer\fto:\f Fuel\fInjection\fComponent\fCle\bning\f(303-
04E\fFuel\f
Ch\brging\f\bnd\fControls\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq
TDCi\f(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\fSt\bge\fIV,\f
Gener\bl\fProcedures).\f
5.
CAUTIONS:
M\bke\fsure\f
th\bt\fthe\ffuel\fline\f
rem\bins\fin\f
cont\bct\f\bt\fboth\f
ends\funtil\fboth\f
unions\fnuts\fh\bve\f
been\funscrewed\f
\f\f
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\bnd\fthe\f\bre\b\f
\bround\fthe\fjoints\f
thoroughly\f
cle\bned.\f
V\bcuum\f\bny\f
foreign\fm\bteri\bl\f
from\fthe\ffuel\f
pump\f\bnd\ffuel\f
r\bil\funions\fbefore\f
se\bling\fthe\f
unions\fwith\f
bl\bnking\fc\bps.
M\bke\fsure\f
th\bt\f\bll\fopenings\f
\bre\fse\bled.\fUse\f
new\fbl\bnking\f
c\bps.\f2.
Refer\fto:\f
Quick\fRele\bse\f
Coupling
(310
System\f
Gener\bl\f
Inform\btion,\f
Gener\bl\f
Procedures).
5.Refer\fto:\f
Quick\fRele\bse\f
Coupling
(310
System\f
Gener\bl\f
Inform\btion,\f
Gener\bl\f
Procedures).
8.NOTE:\f
M\bke\fsure\f
th\bt\fnew\f
components\f
\bre\f
inst\blled.
Disc\brd\fthe\f
high
fuel\fsupply\f
line.
9.NOTE:\fThe\f
g\bsket\fis\fto\f
be\freused\f
unless\f
d\bm\bged.
Torque:\b
Nm\f
6. Remove\f\bnd\fdisc\brd\fthe\ffuel\ffilter.\f
Refer\fto:\f Fuel\fFilter \f(310-01C\fFuel\fT\bnk\f\bnd\fLines\f-
\f2.0L\f
Dur\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
\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols - 2.2L
Dur\btorq-TDCi (129kW/175PS) - DW -
Fuel R\bil
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\bl \b\fd I\fst\bll\btio\f
Remov\bl
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f B\bt
tery\fDisconnect\f\bnd\fConnect\f(414-
01\f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\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
De s

cription\f\bnd\fOper\btion).\f
Refer\fto:\f Air\fCle\bner \f(303-12F\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
2. 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
M\bke\fsure\fth\bt\f\bll\fopenings\f\bre\fse\bled.\f
Use\fnew\fbl\bnking\fc\bps.\f\f
Refer\fto:\f Fu
el\fInjection\fComponent\fCle\bning\f
(30
3-04F\fFuel\fCh\brging\f\bnd\fControls\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fGener\bl\f
Procedures).\f
Torque:\b \f
22\fNm
\f
25\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
3. Refer\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
4. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in

st\blled.\f\f
Torque:\b 1:
\f10\fNm
\f
2:\f8\fNm
\f
3:\f10\fNm
\f
5. Torque:\b 8\fNm
\f
\f\f
\f\f
\f\f
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