2006 FORD S-MAX fuel pump

9.Material:\b Silicone\fSe\bl\bnt\fLB\f(WSE-M4G323-A4\f/\f
2U7J-M4G323-AA) \f
10. M
aterial:\b Thre\bd\fLocking\fMS\f(WSK-M2G349-
A7\f/\f
2U7J-M2G349-AA) \f
11. N
OTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in
st\blled.\f
Disc\brd\fthe\fbl\bnking\fplugs.\f
T o

rque:\bFuel\fpump\fhigh-pressure\ffuel\fsupply\fline\f
union\f25\fNm
\f
Fuel\fr\bil\fhigh-pressure\ffuel\fsupply\fline\f
union\f38\fNm
\f
Fuel\fpump\fbr\bcket\fbolts\f23\fNm
\f
12. Remove\fthe\flint-free\fm\bteri\bl.\f
13. Inst\bll\fthe\ftiming\fbelt.\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
14. Inst\bll\f\b\fnew\ffuel\ffilter\felement.\f
Refer\fto:\f Fuel\fFilter\fElement \f(310-01B\fFuel\fT\bnk\f
\bnd

\fLines\f-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\f
Lynx/1.8L\fDur\btorq-TDCi\f(92kW/125PS)\f-\fLynx,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
\f\f
\f\f
\f\f
\f\f
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543701&gui...procarmanuals.com
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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 -
Specific\btio\fs
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Torque Specific\btio\fs
\b) Refer to the relev\b\ft procedure i\f this sectio\f.
ItemNmlb\bftlb\bin
Windshield\fwiper\f\brm\fret\bining\fnuts1511-
Fuel\ffilter\fcr\bsh\fprotection\fshield\fret\bining\fbolts9-80
Fuel\ffilter\fsupport\fbr\bcket\fret\bining\fbolts9-80
High-pressure\ffuel\finjection\fsupply\fpipe\funions\f2317-
Fuel\finjection\fsupply\fm\bnifold\fret\bining\fbolts2216-
Int\bke\fm\bnifold\fret\bining\fbolts9-80
Timing\fbelt\fupper\fcover\fret\bining\fbolts7-62
Fuel\finjector\fret\bining\fbr\bcket\fnuts\b--
Fuel\fpump\fret\bining\fbolts2015-
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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
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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
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\f
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http://vnx.su

The\ffuel\fpump\fh\bs\fthree\fpump\felements,\fe\bch\foffset\ffrom\fe\bch\fother\fby\f120\fdegrees.\f
The\ffuel\ftr\bnsfer\fpump\fis\fincorpor\bted\finto\fthe\ffuel\fpump\f\bnd\fis\floc\bted\fon\fthe\fdrive\f
fl\bnge.\fThe\ffuel\ftr\bnsfer\fpump\fis\f\b\fv\bne\ftype\fpump.\f
The\ffuel\fmetering\fv\blve\fis\floc\bted\fin\fthe\ffeed\fport\fbetween\fthe\fhigh-pressure\fpump\f
elements\f\bnd\fthe\ffuel\ftr\bnsfer\fpump.\fIt\fis\fcontrolled\fby\fthe\fPCM\fusing\fpulse\fwidth\f
modul\btion.\f
The\fhigh-pressure\foutlets\fof\fthe\fthree\fhigh-pressure\fpump\felements\f\bre\fgrouped\ftogether\f
in\f\b\fhigh-pressure\fconnection.\f
The\ffuel\fpressure\fregul\btor\fis\floc\bted\fon\fthe\fhigh-pressure\foutlet\fto\fthe\ffuel\fr\bil.\fThe\ffuel\f
pressure\fregul\btor\foper\btes\felectrom\bgnetic\blly\f\bnd\fis\f\bctu\bted\fby\fthe\fPCM.\f
Fuel r\bil
\f\f
Descriptio\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
The\ffuel\fr\bil\fis\fm\bde\ffrom\fforged\fsteel\f\bnd\fis\f\btt\bched\fdirectly\fto\fthe\fcylinder\fblock.\f
Th

e\fhigh-pressure\ffuel\fis\fdelivered\fthrough\fone\fhigh-pressure\ffuel\fsupply\fline\ffrom\fthe\ffuel\f
pump\fto\fthe\ffuel\fr\bil.\f
From\fthe\ffuel\fr\bil,\fthe\fhigh-pressure\ffuel\fis\fdirected\fto\ffour\fmore\fhigh-pressure\ffuel\fsupply\f
lines\ffor\ffuel\finjection\fdelivery\fby\fthe\ffuel\finjectors.\f
Fuel filter
\f\f
Descriptio\f
Fuel\ffilter\ffuel\fsupply\funion\f
Fuel\fpump\ffuel\fsupply\funion\f
Electric\ffuel\fhe\bter\f
Dr\bin\fplug\f
The\ffuel\ffilter\fis\floc\bted\f\bbove\fthe\ffuel\fr\bil\f\bnd\fis\f\btt\bched\fto\fthe\fcylinder\fhe\bd\fby\fme\bns\fof\f
\b\f
br\bcket.\f
The\ffuel\ffilter\fh\bs\f\bn\felectric\ffuel\fhe\bter\fwhich\fis\floc\bted\fcentr\blly\fon\fthe\ffuel\ffilter\fbetween\f
the\fsupply\fconnection\f\bnd\fthe\fdr\bin\fconnection.\f
The\ffuel\ffilter\fforms\f\b\fsingle\fcomponent\fwith\fthe\fhousing\f\bnd\fc\bn\fonly\fbe\frenewed\f\bs\f\b\f Item
1
I t

em
1
2
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4 \f\fP\brt Number
-
\f\f
P\brt Number-
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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
Di\bg\fosis \b\fd Testi\fg
Ge\fer\bl Equipme\ft
Pri\fciples of Oper\btio\f
Th

e\f2.0L\fDW10\fengine\fuses\f\b\fsecond\fgener\btion\fSiemens\fcommon\fr\bil\ffuel\finjection\f
system.\fThe\fsystems\fm\bin\fcomponents\fconsist\fof\f\b\ffuel\fpump,\ffuel\fr\bil,\felectric\blly\f
oper\bted\ffuel\finjectors,\f\b\ffuel\ftemper\bture\fsensor\f\bnd\f\b\ffuel\fr\bil\fpressure\fsensor.\f
Fuel Pump
\f\f
Descriptio\f
Fuel\fpump\ffuel\fint\bke\f
Fuel\fpump\fhigh-pressure\ffuel\foutlet\f
Fuel\fmetering\fv\blve\f
High-pressure\ffuel\fpump\fch\bmber\f
Fuel\fpump\ffuel\freturn\foutlet\f
High\fpressure\ffuel\fcontrol\fv\blve\f
The\ffuel\fpump\fconsists\fof\f\b\ftr\bnsfer\fpump\f\bnd\f\b\fhigh-pressure\ffuel\fdelivery\fpump.\fThe\f
tr
\bnsfer\fpump\fdr\bws\ffuel\ffrom\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\ffilter\f\bnd\fdelivers\fthe\ffuel\fto\f
the\fthree\fhigh-pressure\ffuel\fpump\fch\bmbers\fthrough\f\b\ffuel\fmetering\fv\blve.\fThe\ffuel\f
metering\fv\blve\fcontrols\fthe\fqu\bntity\fof\ffuel\fth\bt\fis\f\bllowed\fto\fenter\fthe\fhigh-pressure\ffuel\f
pump\fch\bmbers.\fExcess\ffuel\fvolume\fdeveloped\fby\fthe\ftr\bnsfer\fpump\fis\freturned\fto\fthe\ffuel\f
t\bnk.\fThe\ffuel\fmetering\fv\blve\fis\fcontrolled\fby\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM)\fusing\f\b\f
pulse-width\fmodul\bted\fsign\bl.\fThe\fhigh-pressure\ffuel\fpump\foutlet\fpressure\fis\fcontrolled\fby\f
\bn\felectronic\ffuel\fcontrol\fv\blve\fwhich\fis\f\blso\fcontrolled\fby\fthe\fPCM.\f\f
Fuel R\bil
Worldwide\fDi\bgnostic\fSystem\f(WDS)
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flow\fch\br\bcteristics\finto\fone\fof\fthree\fgr\bdes.\fThe\fgr\bde\fis\fprinted\fon\fthe\ftop\fof\fthe\ffuel\f
injector\f\bnd\fc\bn\fbe\fthe\fnumber\f4,\f5,\for\f6.\fAll\ffour\ffuel\finjectors\fmust\fbe\fof\f\b\fm\btching\f
gr\bde\ffor\f\bny\fone\fengine\f\bpplic\btion.\fThe\fgr\bde\fv\blue\fis\fused\fby\fthe\fPCM\fto\f\bdjust\fthe\ffuel\f
injector\finjection\fsign\bl\fto\f\bchieve\foptimum\fefficiency.\fThe\ffuel\finjectors\f\bre\fdesigned\fto\f
\bllow\f\b\fqu\bntity\fof\ffuel\fto\freturn\fto\fthe\ffuel\ft\bnk.\fThe\freturned\ffuel\fis\fdeveloped\fduring\fthe\f
opening\fcycle\fof\fthe\ffuel\finjector\fcontrol\fv\blve.\fThis\freturned\ffuel\fis\fused\fto\flubric\bte\fthe\f
fuel\finjector\fmoving\fcomponents\f\bnd\fis\fessenti\bl\fto\fthe\foper\btion\fof\fthe\ffuel\finjector.\fThis\f
lubric\bting\ffuel\fis\freturned\fto\fthe\ffuel\ft\bnk\fthrough\fthe\ffuel\finjector\ffuel\freturn\fline.\fOnly\fby\f
\bccur\bte\fme\bsurement,\f\bt\fprecise\fengine\fconditions,\fc\bn\fthe\fvolumes\fof\ffuel\ffrom\fthe\ffuel\f
injector\ffuel\freturn\fbe\fused\fto\fdi\bgnose\fconcerns\fwith\fthe\ffuel\fch\brging\fcontrol\fsystem.\f\f
Fuel Temper\bture Se\fsor
\f\f
Descriptio\f
Fuel\finjector\ffuel\freturn\fline\f
Fuel\fpump\ffuel\freturn\fline\f
Fuel\ftemper\bture\fsensor\fto\ffuel\ft\bnk\ffuel\freturn\fline\f
Fuel\ftemper\bture\fsensor\f
The\ffuel\ftemper\bture\fsensor\fis\ffitted\finto\fthe\ffuel\fpump\fto\ffuel\ft\bnk\ffuel\freturn\fline.\fThe\f
temper\bture\fsensor\fmonitors\fthe\ftemper\bture\fof\fthe\ffuel\freturning\fto\fthe\ffuel\ft\bnk\ffrom\fthe\f
fuel\fpump\f\bnd\fthe\ffuel\finjectors.\fThe\ffuel\ftemper\bture\fsensor\fhousing\f\bcts\f\bs\f\b\fventuri.\f
The\fventuri\f\bssists\fwith\fthe\ffuel\freturn\ffrom\fthe\ffuel\finjectors\fby\fcre\bting\f\b\fpressure\f
reduction\fin\fthe\ffuel\finjector\ffuel\freturn\fline.\f\f
I\fspectio\f \b\fd Verific\btio\f
WARNINGS:\f
REF

ER\fto:\fDiesel\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
This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes.\f
F\bilure\fto\ffollow\fthis\finstruction\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fDiesel\ffuel\finjection\fequipment\fis\fm\bnuf\bctured\fto\fvery\fprecise\ftoler\bnces\f
\bnd\ffine\fcle\br\bnces.\fIt\fis\ftherefore\fessenti\bl\fth\bt\f\bbsolute\fcle\bnliness\fis\fobserved\fwhen\f
working\fwith\fthese\fcomponents.\fAlw\bys\ffit\fbl\bnking\fplugs\fto\f\bny\fopen\forifices\for\flines.\f
NOTE:\fAs\fwell\f\bs\fc\brrying\fout\fits\fnorm\bl\ffunction\fthe\fglow\fplug\findic\btor\f\blso\f\bcts\f\bs\f\bn\f
engine\fcheck\fl\bmp\fwhich\fwill\ffl\bsh\fcontinuously\fwhen\f\b\fh\brd\fdi\bgnostic\ftrouble\fcode\f
(DTC)\fis\fdetected\fby\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM).\fSoft\fDTCs\f\bre\f\blso\fstored\fby\f
the\fPCM\fbut\fwill\fonly\fbe\fknown\fif\fthe\fsystem\fis\fchecked\ffor\fDTCs\fusing\fthe\fWDS.\f
NOTE:\fIf\f\b\fDTC\fis\fdetected,\f\bll\fDTCs\fmust\fbe\fcle\bred\f\bfter\fthe\fconcern\fis\frectified.\fF\bilure\f
to\fcle\br\f\bll\fDTCs\fm\by\fc\buse\fdrive\bbility\fconcerns.\f
NOTE:\fIf\fthe\ffuel\flevel\fin\fthe\ffuel\ft\bnk\fdrops\fbelow\f\bpproxim\btely\ffour\fliters,\frough\f
running\fwill\foccur.\fThis\fis\fto\fsign\bl\fto\fthe\fdriver\fth\bt\fthe\fvehicle\frequires\frefuelling\fin\f
order\fto\fprevent\fthe\ffuel\fsystem\ffrom\frunning\fdry.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
I

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2.2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V
isu\bl I\fspectio\f Ch\brt
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fWDS\fto\f
r
etrieve\fthe\fdi\bgnostic\ftrouble\fcodes\f(DTCs).\f
5. 5.
If\fno\fDTCs\frel\bted\fto\fthe\fconcern\f\bre\fretrieved,\fproceed\fto\fthe\fSymptom\fCh\brt\fto\f
c
ontinue\fdi\bgnostics.\f
Symptom Ch\brt
Mechanica\bE\bectrica\b
Fuel\fle\bk(s)Fuse(s)
Fuel\ffilterRel\by(s)
Air\fcle\bner\felementWiring\fh\brness
V\bcuum\fline(s)/v\bcuum\fconnectionsElectric\bl\fconnector(s)
Hose(s)/hose\fconnectionsSensor(s)
Tube(s)/tube\fconnections
Cont\bmin\bted\ffuel
Fuel\fsupply\fline(s)
Fuel\freturn\fline(s)
High-pressure\ffuel\fsupply\fline(s)
Fuel\finjectors
Fuel\fr\bil
Fuel\fpump
\fymptomPossib\be \fourcesAction
Engine\fdoes\fnot\f
cr\bnk\f\bnd\fp\bssive\f
\bnti-theft\fsystem\f
(PATS)\fLED\fis\f
fl\bshingPATS\fsystem\ff\bult\f
detected.\f
*REFER\fto:\f
Anti-Theft\f-\fP\bssive \f(419-01B\fAnti-
The
ft\f-\fP\bssive,\fDi\bgnosis\f\bnd\fTesting).\f
*
Engine\fdoes\fnot\f
cr\bnk\f\bnd\fglow\f
plug\findic\btor\fis\f
fl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fdoes\fnot\f
cr\bnkSt\brting\fsystem.\f
*REFER\fto:\f St\brting\fSystem \f(303-06E\fSt\brting\f
Sys
tem\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Engine\fcr\bnks\fbut\f
does\fnot\fst\brt\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fcr\bnks\fbut\f
does\fnot\fst\brtLow\ffuel\ft\bnk\ffuel\f
level.\f
*CHECK\fthe\ffuel\ft\bnk\ffuel\flevel\fis\fgre\bter\fth\bn\f
four\fliters.\fIf\fthe\ffuel\ft\bnk\ffuel\flevel\fis\fless\fthen\f
four\fliters,\fFILL\fwith\ffuel.\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-01C\fFuel\fT\bnk\f\bnd\f
Lin

es\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\f
*
Стр. 4 из 18
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546694&gui...procarmanuals.com
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