Page 1537 of 4402

Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Turboch\brger.\f
*REFER\fto:\fTurboch\brger\f(303-04G\fFuel\f
Ch\brging\f\bnd\fControls\f-\fTurboch\brger\f-\f2.0L\f
Dur\btorq-TDCi\f(DW)\fDiesel,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Slipping\fclutch\f(If\f
equipped).\f
*REFER\fto:\fM\bnu\bl\fTr\bns\bxle\f\bnd\fClutch\f(308-
00\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-
\f
Gener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
*
Low\fcylinder\f
compression.\f
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
ECT\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAF\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
MAP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
Int\bke\f\bir\fshut-off\f
throttle.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fbutterfly\f
for\fobstructions\f\bnd\fcorrect\foper\btion.\f\f
REFER\fto\fthe\fWDS.\f
*
*
Int\bke\f\bir\fshut-off\f
throttle\fv\bcuum\f
control\fsolenoid.\f
*CHECK\fthe\fint\bke\f\bir\fshut-off\fthrottle\fv\bcuum\f
control\fsolenoid\fv\bcuum\flines\ffor\fkinks\for\f
restrictions.\f REFER\fto\fthe\fWDS.\f
*
*
Engine\fcuts\fout\f
during\fh\brd\f
\bcceler\btionCMP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
FRP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
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Page 1538 of 4402

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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Page 1539 of 4402
5. Remove\f\bll\ftr\bces\fof\fev\bpor\btive\fcle\bning\f\bgent\f\bnd\fforeign\fm\bteri\bl.\f
General \fquipment\b Pneum\btic\fv\bcuum\fgun\f
6. D
ispose\fof\f\bny\funused\fev\bpor\btive\fcle\bning\f
\bgent\f\bnd\fthe\fbrush\f\bfter\fcompleting\fthe\frep\bir.\f
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Page 1540 of 4402

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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Page 1541 of 4402
I\fst\bll\btio\f 7.
CAUTIONS:
Use\f\bn\f
open-ended\f
wrench\fto\f
prevent\fthe\f
component\f
from\fturning.\f
M\bke\fsure\f
th\bt\fthe\ffuel\f
line\frem\bins\fin\f
cont\bct\f\bt\fboth\f
ends\funtil\fboth\f
unions\fnuts\f
h\bve\fbeen\f
unscrewed\f\bnd\f
the\f\bre\b\f
\bround\fthe\f
joints\f
thoroughly\f
cle\bned.
M\bke\fsure\f
th\bt\f\bll\f
openings\f\bre\f
se\bled.\fUse\f
new\fbl\bnking\f
c\bps.\f
Disc\brd\fthe\fhigh
pressure\ffuel\f
supply\flines.
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f
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Page 1542 of 4402
2.CAUTION:\f
Use\f\bn\fopen
ended\fwrench\f
to\fprevent\fthe\f
component\f
from\fturning.\f
NOTE:\fM\bke\f
sure\fth\bt\fnew\f
components\f
\bre\finst\blled.
Tighten\fthe\ffuel\f
r\bil\fnuts\f\bnd\f
high-pressure\f
fuel\fsupply\fline\f
unions\fin\ftwo\f
st\bges\fin\fthe\f
sequence\f
indic\bted.
Torque:\b
Fuel\fr\bil\f
nuts\f
High
pressure\ffuel\f
supply\fline\f
unions\f
19\fNm
30\fNm
3. \f
\f
\f
Стр. 3 из 3
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Page 1543 of 4402

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
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Page 1544 of 4402
5. \f\f
CAUTIONS:
open
ended\f
wrench\fto\f
prevent\f
the\f
component\f
from\f
turning.
sure\fth\bt\f
the\ffuel\f
line\f
rem\bins\fin\f
cont\bct\f\bt\f
both\fends\f
until\fboth\f
unions\f
nuts\fh\bve\f
been\f
unscrewed\f
\bnd\fthe\f
\bre\b\f
\bround\fthe\f
joints\f
thoroughly\f
cle\bned.
sure\fth\bt\f
\bll\f
openings\f
\f
\f
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