2006 FORD S-MAX drive

qu\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\finjector(s).\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\fin\fthe\ffuel\fr\bil.\f
Fuel pump
\f\f
Descriptio\f
Fuel\fpump\ffuel\freturn\fport\f
Fuel\fpressure\fregul\btor\f
High-pressure\ffuel\fsupply\fline\fport\f
Fuel\fpump\ffuel\fsupply\fport\f
Fuel\fmetering\fv\blve\f
The\ffuel\fpump\fis\fdriven\fclockwise\f\bt\fh\blf\fthe\fengine\fspeed\fby\fthe\ftiming\fbelt.\f
Th

e\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\f\bctu\bted\fby\fthe\fPCM\fusing\fpulse\fwidth\fmodul\btion.\f
The\ffuel\fpressure\fregul\btor\fis\floc\bted\fon\fthe\ffuel\fpump.\fThe\ffuel\fpressure\fregul\btor\f
oper\btes\felectrom\bgnetic\blly\f\bnd\fis\f\bctu\bted\fby\fthe\fPCM.\f
Fuel r\bil Item
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\f\fDescriptio\f
Fuel\finjector\ffuel\freturn\fline\f
Fuel\ftemper\bture\fsensor\f
Fuel\fpump\ffuel\freturn\fline\f
Fuel\ft\bnk\ffuel\freturn\fline\funion\f
The\ffuel\ftemper\bture\fsensor\fis\finst\blled\finto\fthe\ffuel\finjector\fto\ffuel\ft\bnk\ffuel\freturn\fline.\f
Th
e\ftemper\bture\fsensor\fmonitors\fthe\ftemper\bture\fof\fthe\ffuel\freturning\fto\fthe\ffuel\ft\bnk\f
from\fthe\ffuel\finjectors\f\bnd\fsends\f\b\fsign\bl\fto\fthe\fPCM.\f\f
I\fspectio\f \b\fd Verific\btio\f
WARNINGS:\f
Do\f

not\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
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\fFord\f\bpproved\f
di\bgnostic\ftool.\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\flitres,\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
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G504847&gui...procarmanuals.com
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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
Стр. 1 из 5
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543699&gui...procarmanuals.com
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I\fst\bll\btio\f
prevent\fthe\f
component\f
from\f
turning.
\f
M\bke\f
sure\fth\bt\f
the\ffuel\fline\f
rem\bins\fin\f
cont\bct\f\bt\f
both\fends\f
until\fboth\f
unions\fnuts\f
h\bve\fbeen\f
unscrewed\f
\bnd\fthe\f
\bre\b\f\bround\f
the\fjoints\f
thoroughly\f
cle\bned.
V\bcuum\f
\bny\fforeign\f
m\bteri\bl\f
from\fthe\f
fuel\fpump\f
\bnd\ffuel\fr\bil\f
unions\f
before\f
se\bling\fthe\f
unions\fwith\f
bl\bnking\f
c\bps.\f
M\bke\f
sure\fth\bt\f\bll\f
openings\f
\bre\fse\bled.\f
Use\fnew\f
bl\bnking\f
c\bps.\f
General
\bqui\fment:
Fl\bt-bl\bded\f
screwdriver
7. \f
\f
\f\f
Стр. 2 из 5
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1.NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\finst\blled.
2.NOTE:\fM\bke\fsure\fth\bt\fthe\fcomponent\fis\finst\blled\fto\f
the\fposition\fnoted\fbefore\fremov\bl.\f
Torque: \f
5\f

Nm
\f
90
°\f
St\bge\f1:\f
St\bge\f2:\f
3. General \bqui\fment: Long\fnose\fpliers\f
Gen
eral \bqui\fment: Fl\bt-bl\bded\fscrewdriver \f
4. Lo

osen: 5\fturn(s)
\f
5.
NOTE:\fM\bke\fsure\fth\bt\fnew\fcomponents\f\bre\finst\blled.
NOTE:\fOnly\ftighten\fthe\funion\fnuts\ffinger\ftight\f\bt\fthis\f
st\bge.\f
Disc\brd\fthe\fbl\bnking\fc\bps.\f
\f\f
\f\f
\f
\f\f
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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
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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
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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
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546694&gui...procarmanuals.com
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