Page 2387 of 4402

REFER\fto:\fQuick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f4
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\f
pump\ffuel\freturn\fline\f\bnd\ffuel\freturn\fline\funion.\f5
Observe\fthe\fflow\fof\ffuel\fin\fthe\fcle\br\fpl\bstic\fpipe.\f6
Does\fthe\ffuel\ffrom\fthe\ffuel\ft\bnk\fflow\ffreely\fwith\fno\f
restrictions?\f
Ye\b
GO\fto\fPinpoint\fTest\f A.\f\f
No
R
EPAIR\for\fINSTALL\f\b\fnew\ffuel\ffilter\ffuel\fsupply\f
line.\f\f
PINPOINT TEST D : FUEL FILTER FUEL SUPPLY LINE BLOCKA\fE -
VEHICLES WITH 2.0L DURATORQ-TDCI (DW) DIESEL EN\fINE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
D1: 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
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
\f\f
\f\f
\f\f
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Page 2389 of 4402

Fuel Sy\btem - \feneral Information - Fuel
Tank DrainingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
\feneral Equipment
Fuel\ft\bnk\fdr\bining\fequipment
1. 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. Disconnect\fthe\fb\bttery\fground\fc\bble.\f
Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f
B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
3. \f
4. Connect\fthe\ffuel\ft\bnk\fdr\bin\fequipment\fground\f c\bble\fto\fthe\fvehicle.\f
General \bqui\fment: Fuel\ft\bnk\fdr\bining\f
equ
ipment \f
5. D
r\bin\fthe\ffuel\ft\bnk.\f
6. WARNING:\fFuel\fm\by\fstill\fbe\fpresent\fin\f
th
e\ffuel\ft\bnk\f\bfter\fdr\bining.\f
Remove\fthe\ffuel\ft\bnk\fdr\bin\fequipment.\f
7. \f
\f\f
\f
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Page 2391 of 4402

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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Page 2394 of 4402
Fuel Sy\btem - \feneral Information - Quick
Relea\be CouplingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
\feneral Procedure\b
\feneral Equipment
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
In f
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
Fl\bt-bl\bded\fscrewdriver
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. \f
3. \f
4. \f
5. \f
\f\f
\f\f
\f\f
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Page 2396 of 4402

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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Page 2414 of 4402
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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Page 2431 of 4402

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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Page 2432 of 4402
Vehicles\fwith\ffuel\ffired\fbooster\fhe\bter\f
All\fvehicles\f
12. \f
13
. WARNING:\fBe\fprep\bred\fto\fcollect\f
e s
c\bping\ffluid.\f
Refer\fto:\f Qu
ick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
14. \f
15. CAUTIONS:\f
Us
e\fsuit\bble\fp\bcking\fm\bteri\bl\fto\fprevent\f
d\bm\bge\fto\fthe\fcomponent.\f
M\bke\fsure\fth\bt\fno\fstr\bin\fis\fpl\bced\fon\f
the\ffuel\flines\f\bnd\fwiring\fh\brnesses.\f
Genera\f\bEquipment:\b Tr
\bnsmission\fj\bck\f
Gen
era\f\bEquipment:\b Wooden\fBlock\f
16.Torque:\b 24\fNm\f
17. Genera\f\bEquipment:\b Ret\bining\fStr\bp\f
\f\f
\f\f
\f\f
\f\f
\f\f
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