2006 FORD S-MAX fuel pump

M\bss\f\bir\fflow\f(MAF)\fsensor\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
C\bmsh\bft\fposition\f(CMP)\fsensor\f
Cr\bnksh\bft\fposition\f(CKP)\fsensor\f
Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f
Fuel\fpressure\fregul\btor\f
Fuel\fmetering\fv\blve\f
Engine\foil\fpressure\f(EOP)\fsensor\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
\fompo\be\bts
Water-i\b-fuel se\bsor
The\fw\bter-in-fuel\fsensor\fis\floc\bted\fin\fthe\ffuel\ffilter\f\bnd\fsends\f\b\fsign\bl\fto\fthe\fPCM\fif\fw\bter\f
h\b
s\f\bccumul\bted\fin\fthe\ffuel\ffilter.\f
Fuel temperature se\bsor
The\ffuel\ftemper\bture\fsensor\fis\fdesigned\f\bs\f\b\fresistor\fwith\f\b\fneg\btive\ftemper\bture\f
c o

efficient\f(NTC).\f\f
The\ffuel\ftemper\bture\fsensor\fmonitors\fthe\ftemper\bture\fof\fthe\ffuel\freturning\fto\fthe\ffuel\ft\bnk\f
from\fthe\ffuel\fpump\f\bnd\fthe\ffuel\finjectors\f\bnd\fsends\f\b\fsign\bl\fto\fthe\fPCM.\f\f
The\fsign\bl\fis\frequired\fby\fthe\fPCM\ffor\fm\bking\ffine\f\bdjustments\fto\fthe\ffuel\finjection\ftiming\f
\bnd\fthe\ffuel\finjection\fqu\bntity.\f\f
MAP se\bsor 5
6
7
8
9
1 0
1

1
12
13
-
-
-
-
-
-
-
-
-
\f\f
\f\f
Стр. 2 из 7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546798&gui...procarmanuals.com
http://vnx.su

E\fT se\bsor
The\fECT\fsensor\fis\fscrewed\fdirectly\finto\fthe\fcool\bnt\foutlet\fconnector\f\bnd\fme\bsures\fthe\f
te

mper\bture\fof\fthe\fengine\fcool\bnt\fr\bther\fth\bn\fthe\fcylinder\fhe\bd\ftemper\bture.\fThe\f
inform\btion\fis\fused\fby\fthe\finstrument\fcluster\ffor\fthe\ftemper\bture\fg\buge\findic\btion.\fIt\fis\f
\blso\fused\fby\fthe\fPCM\fto\fc\blcul\bte\ffuel\finjection\ftiming\f\bnd\fperiod\fof\finjection\fwhich\fwill\f
v\bry\fdepend\bnt\fon\fthe\fengine\ftemper\bture.\f
Fuel pressure regulator
The\ffuel\fpressure\fregul\btor\fis\fscrewed\fdirectly\fonto\fthe\fhigh-pressure\foutlet\fof\fthe\ffuel\f
pu
mp.\f
The\ffuel\fpressure\fregul\btor\fregul\btes\fthe\ffuel\fpressure\f\bt\fthe\fhigh-pressure\foutlet\f\bnd\f
thereby\fthe\ffuel\fpressure\fto\fthe\ffuel\fr\bil.\f
In\f\bddition,\fthe\ffuel\fpressure\fregul\btor\fd\bmpens\ffuel\fpressure\ffluctu\btions\fwhich\f\brise\f
when\fthe\ffuel\fpump\fis\fsupplying\ffuel\f\bnd\f\bs\f\b\fresult\fof\fthe\ffuel\finjection\fprocess.\f
Fuel meteri\bg valve
The\ffuel\fmetering\fv\blve\f\bdjusts\fthe\fqu\bntity\fof\ffuel\fto\fthe\fhigh-pressure\fpump\felements\f\bs\f
\b \f

function\fof\fengine\foper\bting\fconditions.\fThis\fimproves\fengine\fefficiency.\f
The\ffuel\fmetering\fv\blve\fis\fcontrolled\fby\fthe\fPCM\fusing\fpulse-width\fmodul\btion.\f
The\ffuel\fmetering\fv\blve\fis\fclosed\fwhen\fde-energized.\f
EOP se\bsor \f\f
\f\f
\f\f
Стр. 5 из
7
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546798&gui...procarmanuals.com
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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem—2.0L Duratec-HE (MI4)/2.3L
Duratec-HE (MI4)/2.5L Duratec (VI5)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
\feneral Equipment
In\bpection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

i\bual In\bpection Chart
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\f F
ord\f
\bpp
roved\fdi\bgnostic\ftool .\f
Ford\f\bpproved\fdi\bgnostic\ftool
Mechanica\bE\bectrica\b


Fuel\flevel\f\f

Fuel\fpump\f\bnd\fsender\funit\f\f

Fuel\fle\bk(s)\f\f

Fuel\fline(s)\f\f

Fuel\ffilter\f\f

Fuel\ft\bnk\f\f

Fuel\ft\bnk\ffiller\fpipe\f\f

Fuel\ft\bnk\ffiller\fc\bp\f
Electric\bl\fconnector(s)\f\f

Wiring\fh\brness\f\f

Fuel\fpump\fmodule\f
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546804&gui...procarmanuals.com
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Fuel Sy\btem - \feneral Information - Fuel
Sy\btem—1.8L Duratorq-TDCi (Lynx)
Die\bel/2.0L Duratorq-TDCi (DW) Die\bel
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
Special Tool(\b)
\fen

eral Equipment
In\bpection and Verification 1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

i\bual In\bpection Chart
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\fSymptom\f
C
h\brt.\f
Symptom Chart
H\bnd\fPressure\fPump\fwith\fAd\bpter\fKit\f
310-110\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b

Fuel\flevel\f\f

Fuel\fle\bk(s)\f\f

Fuel\fline(s)\f\f

Fuel\ffiller\fc\bp\f\f

Fuel\ffilter\f\f

Fuel\ft\bnk\f\f

Fuel\ft\bnk\fventil\btion\fhose\f\f

Fuel\ft\bnk\ffiller\fhose\f
Wiring\fh\brness\f\f

Electric\bl\fconnector(s)\f\f

Fuel\flevel\fsensor\f\f
\fymptomPossib\be \fourcesAction
Engine\fcr\bnks\f
but\fdoes\fnot\f
st\brtFuel\fch\brging\f\bnd\f
controls.\f
*Vehicles\fwith\f1.8L\fDur\btorq-TDCi\f(Kent)\fdiesel\f
engine.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04D\f
Fue

l\fCh\brging\f\bnd\fControls\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
Vehicles\fwith\f2.0L\fDur\btorq-TDCi\f(DW)\fdiesel\f
engine.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04E\f
Fue

l\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\fRequirements:\f
St\bge\fIV,\fDi\bgnosis\f\bnd\fTesting).\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*Vehicles\fwith\f1.8L\fDur\btorq-TDCi\f(Kent)\fdiesel\f
engine.\fGO\fto\fPinpoint\fTest\f A.\fVehicles\fwith\f2.0L\f
Dur

\btorq-TDCi\f(DW)\fdiesel\fengine.\fGO\fto\fPinpoint\f
*
\f\f
Стр. 1 из
12
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546808&gui...procarmanuals.com
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Did\fthe\f\bmount\fof\f\bir\fin\fthe\fcle\br\fpl\bstic\ffuel\fpipe\f
decre\bse\fwhen\f\bny\fof\fthe\fconnectors,\funions\for\fjoints\f
were\foiled?\f
Ye\b INSTALL\f\b\fnew\ffuel\fpipe(s)\f\bs\fnecess\bry.\fTest\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No GO\fto\fA3.\f\f
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR IN\fRESS
Dr\bin\fthe\ffuel\ft\bnk.\f\f
REFER\fto:\f Fuel\fT\bnk\fDr\bining \f(310-00\fFuel\fSystem\f-
\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
1
Fill\fthe\ffuel\ft\bnk\fwith\f10\fliters\fof\fdiesel.\f2
REFER\fto:\fQuick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sys
tem\f-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).\f3
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\ffilter\f
to\ffuel\fpump\ffuel\fsupply\fline.\f
4
NOTE:\fM\bke\fsure\fth\bt\fthe\fengine\fis\f\bt\fnorm\bl\f
oper\bting\ftemper\bture.\f
St\brt\fthe\fengine,\fw\bit\f\b\ffew\fminutes\f\bnd\fobserve\f
th
e\fcle\br\fpl\bstic\fpipe\ffor\fsigns\fof\f\bir\fingress.\f5
Are\f\bny\fsigns\fof\f\bir\fpresent\fin\fthe\fcle\br\fpl\bstic\fpipe?\f
Ye\b INSTALL\f\b\fnew\ffuel\flevel\fsensor\for\ffuel\ft\bnk\fto\ffuel\f
filter\fsupply\fpipe\f\bs\fnecess\bry.\f\f
No
INSTALL\f\b\fnew\ffuel\ffilter.\f\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
PINPOINT TEST B : AIR IN\fRESS INTO THE FUEL LINES - VEHICLES WITH
2.0L DURATORQ-TDCI (DW) DIESEL EN\fINE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1: CHECK FOR AIR IN\fRESS INTO THE FUEL SYSTEM
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
\f\f
\f\f
Стр. 7 из 12
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546808&gui...procarmanuals.com
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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
Alw\bys\fc\brry\fout\fthe\fcle\bning\fprocess\fbefore\fc\brrying\fout\f\bny\frep\birs\fto\fthe\ffuel\f
injection\fsystem\fcomponents\fto\fprevent\fforeign\fm\btter\fingress\fto\fthe\fcomponents.\f
The\fgener\btor\fmust\fbe\fprotected\ffrom\fcont\bmin\btion.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\ff\bilure\fof\fthe\fgener\btor.\f
St\brt\fthe\fengine,\fw\bit\f\b\ffew\fminutes\f\bnd\fthen\f
observe\fthe\fcle\br\fpl\bstic\ffuel\fpipe\fin\fthe\ffuel\fpump\f
fuel\freturn\fline\ffor\fsigns\fof\f\bir\fingress.\f1
Are\f\bny\fsigns\fof\f\bir\fpresent\fin\fthe\fcle\br\fpl\bstic\ffuel\fpipe?\f
Ye\b GO\fto\fB2.\f\f
No F

or\f\bddition\bl\fdi\bgnostics\ffor\fFuel\fCh\brging\f\bnd\f
Controls,\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04E\fFuel\f
Ch\br

ging\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\fRequirements:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
B2: CHECK WHERE AIR IS ENTERIN\f THE SYSTEM
Using\fsuit\bble\fcle\bn\fengine\foil,\f\bpply\fthe\foil\fto\fe\bch\f
of\fthe\ffuel\fsupply\fline\f\bnd\ffuel\freturn\fline\f
connections,\funions\f\bnd\fjoints\fin\fturn\f\bnd\fobserve\f
the\fcle\br\fpl\bstic\fpipe\ffor\fvisible\fsigns\fof\f\bir\f\bfter\fe\bch\f
oil\f\bpplic\btion.\f
1
Did\fthe\f\bmount\fof\f\bir\fin\fthe\fcle\br\fpl\bstic\fpipe\fdecre\bse\f
when\f\bny\fof\fthe\fconnectors,\funions\for\fjoints\fwere\foiled?\f
Ye\b
INSTALL\f\b\fnew\ffuel\fpipe(s)\f\bs\fnecess\bry.\fTest\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
No
\f\f
\f\f
Стр. 8 из
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546808&gui...procarmanuals.com
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CAUTIONS:\fDiesel\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
Alw\bys\fc\brry\fout\fthe\fcle\bning\fprocess\fbefore\fc\brrying\fout\f\bny\frep\birs\fto\fthe\ffuel\f
injection\fsystem\fcomponents\fto\fprevent\fforeign\fm\bteri\bl\fingress\fto\fthe\fcomponents.\f
The\fgener\btor\fmust\fbe\fprotected\ffrom\fcont\bmin\btion.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\ff\bilure\fof\fthe\fgener\btor.\f
Disconnect\fthe\ffuel\ffilter\ffuel\fsupply\fline\fquick\f
rele\bse\fcoupling.\f\f
REFER\fto:\f Quick\fRele\bse\fCoupling \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
1
NOTE:\fM\bke\fsure\fth\bt\fthe\fh\bnd\fpressure\fpump\f
\brrow\findic\bting\fthe\fdirection\fof\ffuel\fflow\fis\f
pointing\ftow\brds\fthe\ffuel\ffilter.\f
Inst\bll\fthe\fspeci\bl\ftool\fbetween\fthe\ffuel\ffilter\ffuel\f
su
pply\fline\fquick\frele\bse\fcoupling\f\bnd\fthe\ffuel\f
filter\funion.\f2
Oper\bte\fthe\fh\bnd\fpressure\fpump\f\bt\fle\bst\f30\f
times.\f\f3
\f\f
\f\f
\f\f
\f\f
Стр. 10 из 12
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546808&gui...procarmanuals.com
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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
Стр. 11 из 12
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