2006 FORD S-MAX Service Repair Manual

trunk release stop start suspension reset headrest tire type

Page 2377 of 4402

$FORD S-MAX 2006 Service Repair Manual Fuel Sy\btem - \feneral Information - Fuel Sy\btem—1.8L Duratorq-TDCi (Lynx) Die\bel/2.0L Duratorq-TDCi (DW) Die\bel S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagno\bi\b and Te\bting Special$

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\fWiring\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
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Page 2378 of 4402

$FORD S-MAX 2006 Service Repair Manual Test\fB.\f\f Cont\bmin\bted\ffuel.\f *DRAIN\f\bnd\fREFILL\fthe\ffuel\fsystem\fwith\ffresh\ffuel.\f INSTALL\f\b\fnew\ffuel\ffilter.\f\f REFER\fto:\f Fuel\fFilter\f(310- 01B\fFuel\fT\bnk\f\bnd\fLines\f$

Test\fB.\f\f
Cont\bmin\bted\ffuel.\f
*DRAIN\f\bnd\fREFILL\fthe\ffuel\fsystem\fwith\ffresh\ffuel.\f
INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-
01B\fFuel\fT\bnk\f\bnd\fLines\f
-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\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-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Poor\fst\brtingFuel\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
Test\f B.\f\f
*
Cont\bmin\bted\ffuel.\f
*DRAIN\f\bnd\fREFILL\fthe\ffuel\fsystem\fwith\ffresh\ffuel.\f
INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-
01B\fFuel\fT\bnk\f\bnd\fLines\f
-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\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-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Engine\fst\brts\fbut\f
immedi\btely\f
stops
Fuel\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
Test\f B.\f\f
*
Poor\fidlingFuel\fch\brging\f\bnd\f
*Vehicles\fwith\f1.8L\fDur\btorq-TDCi\f(Kent)\fdiesel\f
*
Стр. 2 из 12
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Page 2379 of 4402

$FORD S-MAX 2006 Service Repair Manual controls.\fengine.\f\f REFER\fto:\fFuel\fCh\brging\f\bnd\fControls \f(303-04D\f Fue l\fCh\brging\f\bnd\fControls\f-\f1.8L\fDur\btorq-TDCi\f (74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f (92kW/125PS)\f$

controls.\fengine.\f\f
REFER\fto:\fFuel\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
Test\f B.\f\f
*
Cont\bmin\bted\ffuel.\f
*DRAIN\f\bnd\fREFILL\fthe\ffuel\fsystem\fwith\ffresh\ffuel.\f
INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-
01B\fFuel\fT\bnk\f\bnd\fLines\f
-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\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-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Engine\fl\bcks\f
powerFuel\ft\bnk\fto\ffuel\f
filter\ffuel\fsupply\fline\f
blocked.\f
*CHECK\fthe\ffuel\fsupply\flines\ffor\fd\bm\bge.\fINSTALL\f
\b\fnew\ffuel\ffilter\ffuel\fsupply\fline.\f\f Vehicles\fwith\f1.8L\fDur\btorq-TDCi\f(Kent)\fdiesel\f
engine.\fGO\fto\fPinpoint\fTest\f C.\fVehicles\fwith\f2.0L\f
Dur

\btorq-TDCi\f(DW)\fdiesel\fengine.\fGO\fto\fPinpoint\f
Test\f D.\f\f
*
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-
01B\fFuel\fT\bnk\f\bnd\fLines\f
-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\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-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Fuel\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
*
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Page 2380 of 4402

$FORD S-MAX 2006 Service Repair Manual Dur\btorq-TDCi\f(DW)\fdiesel\fengine.\fGO\fto\fPinpoint\f Test\fB.\f\f Cont\bmin\bted\ffuel.\f *DRAIN\f\bnd\fREFILL\fthe\ffuel\fsystem\fwith\ffresh\ffuel.\f INSTALL\f\b\fnew\ffuel\ffilter.\f\f REFER\f$

Dur\btorq-TDCi\f(DW)\fdiesel\fengine.\fGO\fto\fPinpoint\f
Test\fB.\f\f
Cont\bmin\bted\ffuel.\f
*DRAIN\f\bnd\fREFILL\fthe\ffuel\fsystem\fwith\ffresh\ffuel.\f
INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-
01B\fFuel\fT\bnk\f\bnd\fLines\f
-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\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-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Engine\fmisfireFuel\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
Test\f B.\f\f
*
Excessive\ffuel\f
consumptionFuel\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
Fu e

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
Test\f B.\f\f
*
Cont\bmin\bted\ffuel.\f
*DRAIN\f\bnd\fREFILL\fthe\ffuel\fsystem\fwith\ffresh\ffuel.\f
INSTALL\f\b\fnew\ffuel\ffilter.\f\f
REFER\fto:\f Fuel\fFilter\f(310-
01B\fFuel\fT\bnk\f\bnd\fLines\f
-\f1.8L\fDur\btorq-TDCi\f(74kW/100PS)\f-\fLynx/1.8L\f
Dur\btorq-TDCi\f(92kW/125PS)\f-
\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion)\f/\f\f
Fuel\fFilter\f(310-01C\fFuel\fT\bnk\f\bnd\fLines\f-\f2.0L\f
Du r

\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,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
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Page 2381 of 4402

$FORD S-MAX 2006 Service Repair Manual Pinpoint Te\bt\b Fuel\ffiller\fnozzle\f shuts\foff\f prem\bturelyFuel\ft\bnk\fventil\btion\f hose\for\fpipe\f blocked.\f Fuel\ft\bnk\fventil\btion\f hose\for\fpipe\f coll\bpsed.\f * * CHECK\fthe\ffue$

Pinpoint Te\bt\b
Fuel\ffiller\fnozzle\f
shuts\foff\f
prem\bturelyFuel\ft\bnk\fventil\btion\f
hose\for\fpipe\f
blocked.\f
Fuel\ft\bnk\fventil\btion\f
hose\for\fpipe\f
coll\bpsed.\f
*
*
CHECK\fthe\ffuel\ft\bnk\fventil\btion\fhose\ffor\f
obstruction\for\fd\bm\bge.\fINSTALL\f\b\fnew\ffuel\ft\bnk\f
ventil\btion\fpipe.\f
*
Fuel\ft\bnk\ffiller\fpipe\f
or\fhose\fblocked.\f Fuel\ft\bnk\ffiller\fpipe\f
or\fhose\fcoll\bpsed.\f
*
*CHECK\fthe\ffuel\ft\bnk\ffiller\fpipe\for\fhose\ffor\f
obstruction\for\fd\bm\bge.\fINSTALL\f\b\fnew\ffuel\ft\bnk\f
filler\fpipe.\f
*
Fuel\fg\buge\f
indic\btion.\f
*CHECK\fthe\ffuel\flevel\fin\fthe\ffuel\ft\bnk.\fCHECK\fthe\f
fuel\findic\btion\fsystem.\fFor\f\bddition\bl\finform\btion,\f
\f
REFER\fto:\f Instrument\fCluster \f(413-01\fInstrument\f
Clu
ster,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\ffiller\fnozzle\f\bt\f
fuel\ffilling\fst\btion\fnot\f
functioning\fcorrectly.\f
*VERIFY\fcondition\fby\fusing\f\b\fknown\fgood\ffuel\ffiller\f
nozzle.\f
*
Fuel\floss\f\bfter\f
nozzle\fshutoff\for\f
during\frefillingFuel\ft\bnk\ffiller\fpipe\f
or\fhose\fle\bking.\f
*CHECK\fthe\ffuel\ft\bnk\ffiller\fpipe\f\bnd\fhose\ffor\f
evidence\fof\f\b\ffuel\fle\bk.\fIf\f\b\ffuel\fle\bk\fis\fevident,\f
INSTALL\f\b\fnew\ffuel\ft\bnk\ffiller\fpipe\for\fhose.\f
*
Fuel\ft\bnk\fle\bking.\f
*CHECK\fthe\ffuel\ft\bnk\ffor\fevidence\fof\f\b\ffuel\fle\bk.\fIf\f
\b\ffuel\fle\bk\fis\fevident,\fINSTALL\f\b\fnew\ffuel\ft\bnk.\f\f
*
Fuel\ft\bnk\fventil\btion\f
pipe\for\fhose\fle\bking.\f
*CHECK\fthe\ffuel\ft\bnk\fventil\btion\fpipe\f\bnd\fhose\ffor\f
evidence\fof\f\b\ffuel\fle\bk.\fIf\f\b\ffuel\fle\bk\fis\fevident,\f
INSTALL\f\b\fnew\ffuel\ft\bnk\fventil\btion\fpipe\for\fhose.\f
*
PINPOINT TEST A : AIR IN\fRESS INTO THE FUEL LINES - VEHICLES WITH
1.8L DURATORQ-TDCI (KENT) DIESEL EN\fINE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: 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
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
system\fcomponents\fto\fprevent\fforeign\fm\bteri\bl\fingress\fto\fthe\fcomponents.\f
Стр. 5 из 12
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Page 2382 of 4402

$FORD S-MAX 2006 Service Repair Manual REFER\fto:\fQuick\fRele\bse\fCoupling \f(310-00\fFuel\f Sys tem\f-\fGener\bl\fInform\btion,\fGener\bl\fProcedures).\f1 Using\f\b\fsuit\bble\fpiece\fof\fcle\br\fpl\bstic\fpipe,\f m\bnuf\bcture\f\bnd\f$

Page 2383 of 4402

$FORD S-MAX 2006 Service Repair Manual 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\$

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
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Page 2384 of 4402

$FORD S-MAX 2006 Service Repair Manual This\fprocedure\finvolves\ffuel\fh\bndling.\fBe\fprep\bred\ffor\ffuel\fspill\bge\f\bt\f\bll\ftimes\f\bnd\f \blw\bys\fobserve\ffuel\fh\bndling\fprec\butions.\fF\bilure\fto\ffollow\fthis\finstruction\fm$

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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