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Fuel System - General Information - Fuel

System—2.0L Duratec-HE (MI4)/2.3L S-MAX/Galaxy 2006.5 (02/2006-)
Duratec-HE (MI4)/2.5L Duratec (VI5)
Print

Diagnosis and Testing

General Equipment
Ford approved diagnostic tool

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
Fuel level Electrical connector(s)
Fuel pump and sender unit Wiring harness
Fuel leak(s) Fuel pump module
Fuel line(s)
Fuel filter
Fuel tank
Fuel tank filler pipe
Fuel tank filler cap

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause
(if possible) before proceeding to the next step

4. 4. If the cause is not visually evident, verify the symptom and refer to the Ford
approved diagnostic tool.

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Fuel System - General Information - Fuel

System—1.8L Duratorq-TDCi (Lynx) S-MAX/Galaxy 2006.5 (02/2006-)
Diesel/2.0L Duratorq-TDCi (DW) Diesel
Print

Diagnosis and Testing

Special Tool(s)
Hand Pressure Pump with Adapter Kit
310-110

General Equipment
Worldwide Diagnostic System (WDS)

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
Fuel level Wiring harness
Fuel leak(s) Electrical connector(s)
Fuel line(s) Fuel level sensor
Fuel filler cap
Fuel filter
Fuel tank
Fuel tank ventilation hose
Fuel tank filler hose

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause
(if possible) before proceeding to the next step.

4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.

Symptom Chart

Symptom Possible Sources Action

Engine cranks * Fuel charging and * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
but does not controls. engine.
start REFER to: Fuel Charging and Controls (303-04D
Fuel Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel
engine.
REFER to: Fuel Charging and Controls (303-04E
Fuel Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Diagnosis and Testing).
* Air ingress into the * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
fuel lines. engine. GO to Pinpoint Test A. Vehicles with 2.0L
Duratorq-TDCi (DW) diesel engine. GO to Pinpoint

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Test B.
* Contaminated fuel. * DRAIN and REFILL the fuel system with fresh fuel.
INSTALL a new fuel filter.
REFER to: Fuel Filter (310-01B Fuel Tank and Lines
- 1.8L Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, Removal and
Installation) /
Fuel Filter (310-01C Fuel Tank and Lines - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).
Poor starting * Fuel charging and * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
controls. engine.
REFER to: Fuel Charging and Controls (303-04D
Fuel Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel
engine.
REFER to: Fuel Charging and Controls (303-04E
Fuel Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Diagnosis and Testing).
* Air ingress into the * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
fuel lines. engine. GO to Pinpoint Test A. Vehicles with 2.0L
Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test B.
* Contaminated fuel. * DRAIN and REFILL the fuel system with fresh fuel.
INSTALL a new fuel filter.
REFER to: Fuel Filter (310-01B Fuel Tank and Lines
- 1.8L Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, Removal and
Installation) /
Fuel Filter (310-01C Fuel Tank and Lines - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).
Engine starts but * Fuel charging and * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
immediately controls. engine.
stops REFER to: Fuel Charging and Controls (303-04D
Fuel Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel
engine.
REFER to: Fuel Charging and Controls (303-04E
Fuel Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Diagnosis and Testing).
* Air ingress into the * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
fuel lines. engine. GO to Pinpoint Test A. Vehicles with 2.0L
Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test B.
Poor idling * Fuel charging and * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

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controls. engine.
REFER to: Fuel Charging and Controls (303-04D
Fuel Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel
engine.
REFER to: Fuel Charging and Controls (303-04E
Fuel Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Diagnosis and Testing).
* Air ingress into the * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
fuel lines. engine. GO to Pinpoint Test A. Vehicles with 2.0L
Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test B.
* Contaminated fuel. * DRAIN and REFILL the fuel system with fresh fuel.
INSTALL a new fuel filter.
REFER to: Fuel Filter (310-01B Fuel Tank and Lines
- 1.8L Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, Removal and
Installation) /
Fuel Filter (310-01C Fuel Tank and Lines - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).
Engine lacks * Fuel tank to fuel * CHECK the fuel supply lines for damage. INSTALL
power filter fuel supply line a new fuel filter fuel supply line.
blocked. * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
engine. GO to Pinpoint Test C. Vehicles with 2.0L
Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test D.
* Fuel filter blocked. * INSTALL a new fuel filter.
REFER to: Fuel Filter (310-01B Fuel Tank and Lines
- 1.8L Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, Removal and
Installation) /
Fuel Filter (310-01C Fuel Tank and Lines - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).
* Fuel charging and * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
controls. engine.
REFER to: Fuel Charging and Controls (303-04D
Fuel Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel
engine.
REFER to: Fuel Charging and Controls (303-04E
Fuel Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Diagnosis and Testing).
* Air ingress into the * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
fuel lines. engine. GO to Pinpoint Test A. Vehicles with 2.0L

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Duratorq-TDCi (DW) diesel engine. GO to Pinpoint

Test B.
* Contaminated fuel. * DRAIN and REFILL the fuel system with fresh fuel.
INSTALL a new fuel filter.
REFER to: Fuel Filter (310-01B Fuel Tank and Lines
- 1.8L Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, Removal and
Installation) /
Fuel Filter (310-01C Fuel Tank and Lines - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).
Engine misfire * Fuel charging and * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
controls. engine.
REFER to: Fuel Charging and Controls (303-04D
Fuel Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel
engine.
REFER to: Fuel Charging and Controls (303-04E
Fuel Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Diagnosis and Testing).
* Air ingress into the * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
fuel lines. engine. GO to Pinpoint Test A. Vehicles with 2.0L
Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test B.
Excessive fuel * Fuel charging and * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
consumption controls. engine.
REFER to: Fuel Charging and Controls (303-04D
Fuel Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).
Vehicles with 2.0L Duratorq-TDCi (DW) diesel
engine.
REFER to: Fuel Charging and Controls (303-04E
Fuel Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Diagnosis and Testing).
* Air ingress into the * Vehicles with 1.8L Duratorq-TDCi (Kent) diesel
fuel lines. engine. GO to Pinpoint Test A. Vehicles with 2.0L
Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test B.
* Contaminated fuel. * DRAIN and REFILL the fuel system with fresh fuel.
INSTALL a new fuel filter.
REFER to: Fuel Filter (310-01B Fuel Tank and Lines
- 1.8L Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, Removal and
Installation) /
Fuel Filter (310-01C Fuel Tank and Lines - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).

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Fuel filler nozzle * Fuel tank ventilation * CHECK the fuel tank ventilation hose for
shuts off hose or pipe obstruction or damage. INSTALL a new fuel tank
prematurely blocked. ventilation pipe.
* Fuel tank ventilation
hose or pipe
collapsed.
* Fuel tank filler pipe * CHECK the fuel tank filler pipe or hose for
or hose blocked. obstruction or damage. INSTALL a new fuel tank
* Fuel tank filler pipe filler pipe.
or hose collapsed.
* Fuel gauge * CHECK the fuel level in the fuel tank. CHECK the
indication. fuel indication system. For additional information,
REFER to: Instrument Cluster (413-01 Instrument
Cluster, Diagnosis and Testing).
* Fuel filler nozzle at * VERIFY condition by using a known good fuel filler
fuel filling station not nozzle.
functioning correctly.
Fuel loss after * Fuel tank filler pipe * CHECK the fuel tank filler pipe and hose for
nozzle shutoff or or hose leaking. evidence of a fuel leak. If a fuel leak is evident,
during refilling INSTALL a new fuel tank filler pipe or hose.
* Fuel tank leaking. * CHECK the fuel tank for evidence of a fuel leak. If
a fuel leak is evident, INSTALL a new fuel tank.
* Fuel tank ventilation * CHECK the fuel tank ventilation pipe and hose for
pipe or hose leaking. evidence of a fuel leak. If a fuel leak is evident,
INSTALL a new fuel tank ventilation pipe or hose.

Pinpoint Tests

PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES - VEHICLES WITH
1.8L DURATORQ-TDCI (KENT) DIESEL ENGINE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNINGS:

Do not smoke or carry lighted tobacco of any type when working on or near any fuel
related components. Highly flammable mixtures are always present and may ignite.
Failure to follow these instructions may result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and
always observe fuel handling precautions. Failure to follow this instruction may result in
personal injury.
CAUTIONS:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute cleanliness is observed when working
with these components. Always install blanking plugs to any open orifices or lines.

Always carry out the cleaning process before carrying out any repairs to the fuel
system components to prevent foreign material ingress to the components.

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1 REFER to: Quick Release Coupling (310-00 Fuel

System - General Information, General Procedures).

2 Using a suitable piece of clear plastic pipe,

manufacture and install a pipe between the fuel filter
fuel supply line and fuel filter.

Start the engine, wait a few minutes and then

3
observe the clear plastic fuel pipe between the fuel
filter fuel supply line and fuel filter for signs of air
ingress.
Are any signs of air present in the clear plastic pipe?
Yes
GO to A2.
No
For additional diagnostics,
REFER to: Fuel Charging and Controls (303-04D Fuel
Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).
A2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1 Using suitable clean engine oil, apply the oil to each
of the fuel supply line and fuel return line
connections, unions and joints in turn and observe
the clear plastic pipe for visible signs of air after each
oil application.

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Did the amount of air in the clear plastic fuel pipe

decrease when any of the connectors, unions or joints
were oiled?
Yes
INSTALL a new fuel pipe(s) as necessary. Test the
system for normal operation.
No
GO to A3.
A3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1 Drain the fuel tank.
REFER to: Fuel Tank Draining (310-00 Fuel System -
General Information, General Procedures).
2 Fill the fuel tank with 10 liters of diesel.
3 REFER to: Quick Release Coupling (310-00 Fuel
System - General Information, General Procedures).

4 Using a suitable piece of clear plastic pipe,

manufacture and install a pipe between the fuel filter
to fuel pump fuel supply line.

NOTE: Make sure that the engine is at normal

operating temperature.
5 Start the engine, wait a few minutes and observe
the clear plastic pipe for signs of air ingress.
Are any signs of air present in the clear plastic pipe?
Yes
INSTALL a new fuel level sensor or fuel tank to fuel
filter supply pipe as necessary.
No
INSTALL a new fuel filter.
REFER to: Fuel Filter Element (310-01B Fuel Tank
and Lines - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx,
Removal and Installation).

PINPOINT TEST B : AIR INGRESS INTO THE FUEL LINES - VEHICLES WITH
2.0L DURATORQ-TDCI (DW) DIESEL ENGINE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
WARNINGS:

Do not smoke or carry lighted tobacco of any type when working on or near any fuel
related components. Highly flammable mixtures are always present and may ignite.
Failure to follow these instructions may result in personal injury.

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This procedure involves fuel handling. Be prepared for fuel spillage at all times and
always observe fuel handling precautions. Failure to follow this instruction may result in
personal injury.
CAUTIONS:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute cleanliness is observed when working
with these components. Always install blanking plugs to any open orifices or lines.

Always carry out the cleaning process before carrying out any repairs to the fuel
injection system components to prevent foreign matter ingress to the components.

The generator must be protected from contamination. Failure to follow this

instruction may result in failure of the generator.

1 Start the engine, wait a few minutes and then

observe the clear plastic fuel pipe in the fuel pump
fuel return line for signs of air ingress.

Are any signs of air present in the clear plastic fuel pipe?
Yes
GO to B2.
No
For additional diagnostics for Fuel Charging and
Controls,
REFER to: Fuel Charging and Controls (303-04E Fuel
Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements: Stage
IV, Diagnosis and Testing).
B2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1 Using suitable clean engine oil, apply the oil to each
of the fuel supply line and fuel return line
connections, unions and joints in turn and observe
the clear plastic pipe for visible signs of air after each
oil application.
Did the amount of air in the clear plastic pipe decrease
when any of the connectors, unions or joints were oiled?
Yes
INSTALL a new fuel pipe(s) as necessary. Test the
system for normal operation.
No

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GO to B3.
B3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS
1 Drain the fuel tank.
REFER to: Fuel Tank Draining (310-00 Fuel System -
General Information, General Procedures).
2 Fill the fuel tank with 10 liters of diesel.
3 Protect the generator with lint-free material to
prevent contamination.
4 Disconnect the fuel filter fuel supply line quick
release coupling.
REFER to: Spring Lock Couplings (310-00 Fuel
System - General Information, General Procedures).

5 Using a suitable piece of clear plastic pipe,

manufacture and install a pipe between the fuel filter
and the fuel tank to fuel filter supply line.

6 Remove the lint-free material.

NOTE: Make sure that the engine is at normal
operating temperature.
7 Start the engine, wait a few minutes and then
observe the clear plastic pipe for signs of air ingress.
Are any signs of air present in the clear plastic pipe?
Yes
INSTALL a new fuel level sensor or fuel tank to fuel
filter supply pipe as necessary.
No
INSTALL a new fuel filter.
REFER to: Fuel Filter Element (310-01C Fuel Tank
and Lines - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L
Duratorq-TDCi (103kW/140PS) - DW, Emission
Requirements: Stage IV, Removal and Installation).

PINPOINT TEST C : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE -

VEHICLES WITH 1.8L DURATORQ-TDCI (KENT) DIESEL ENGINE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE
WARNINGS:

Do not smoke or carry lighted tobacco of any type when working on or near any fuel
related components. Highly flammable mixtures are always present and may ignite.
Failure to follow these instructions may result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and
always observe fuel handling precautions. Failure to follow this instruction may result in
personal injury.

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CAUTIONS:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute cleanliness is observed when working
with these components. Always install blanking plugs to any open orifices or lines.

Always carry out the cleaning process before carrying out any repairs to the fuel
injection system components to prevent foreign material ingress to the components.

The generator must be protected from contamination. Failure to follow this

instruction may result in failure of the generator.

1 Disconnect the fuel filter fuel supply line quick

release coupling.
REFER to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).

NOTE: Make sure that the hand pressure pump

arrow indicating the direction of fuel flow is
pointing towards the fuel filter.
2 Install the special tool between the fuel filter fuel
supply line quick release coupling and the fuel
filter union.

3 Operate the hand pressure pump at least 30

times.

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4 REFER to: Quick Release Coupling (310-00 Fuel

System - General Information, General
Procedures).

5 Using a suitable piece of clear plastic pipe,

manufacture and install a pipe between the fuel
pump fuel return line and fuel return line union.

6 Observe the flow of fuel in the clear plastic pipe.

Does the fuel from the fuel tank flow freely with no
restrictions?
Yes
GO to Pinpoint Test A.
No
REPAIR or INSTALL a new fuel filter fuel supply
line.

PINPOINT TEST D : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE -

VEHICLES WITH 2.0L DURATORQ-TDCI (DW) DIESEL ENGINE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE
WARNINGS:

Do not smoke or carry lighted tobacco of any type when working on or near any fuel
related components. Highly flammable mixtures are always present and may ignite.
Failure to follow these instructions may result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and
always observe fuel handling precautions. Failure to follow this instruction may result in
personal injury.
CAUTIONS:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute cleanliness is observed when working
with these components. Always install blanking plugs to any open orifices or lines.

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Always carry out the cleaning process before carrying out any repairs to the fuel
injection system components to prevent foreign matter ingress to the components.

The generator must be protected from contamination. Failure to follow this

instruction may result in failure of the generator.
1 Protect the generator with lint-free material to
prevent contamination.
2 Disconnect the fuel filter fuel supply line quick
release coupling.
REFER to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).

3 Install the special tool between the fuel filter fuel

supply line quick release coupling and the fuel
filter union.

4 Operate the hand pressure pump.

5 Observe the flow of fuel in the clear plastic fuel
pipe in the fuel pump fuel return line.

Does the fuel from the fuel tank flow freely with no
restrictions?
Yes
GO to Pinpoint Test B.
No
REPAIR or INSTALL a new fuel filter fuel supply
line.

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Fuel System - General Information - Fuel

S-MAX/Galaxy 2006.5 (02/2006-)
Tank Draining
Print

General Procedures
General Equipment
Fuel tank draining equipment
1. Refer to: Petrol and Petrol-Ethanol Fuel Systems
Health and Safety Precautions (100-00 General
Information, Description and Operation).
Refer to: Diesel Fuel System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Disconnect the battery ground cable.

Refer to: Battery Disconnect and Connect (414-

01 Battery, Mounting and Cables, General
Procedures).
3.

4. Connect the fuel tank drain equipment ground

cable to the vehicle.

General Equipment: Fuel tank draining

equipment

5. Drain the fuel tank.

6. WARNING: Fuel may still be present in

the fuel tank after draining.
Remove the fuel tank drain equipment.
7.

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8. Connect the battery ground cable.

Refer to: Battery Disconnect and Connect (414-

01 Battery, Mounting and Cables, General
Procedures).

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Fuel System - General Information -

S-MAX/Galaxy 2006.5 (02/2006-)
Spring Lock Couplings
Print

General Procedures
Special Tool(s)
310-040
Disconnect Tool, Fuel Line (5/16")

310-137
Disconnect Tool, Fuel Line

310-D004
Disconnect Tool, Spring Lock Coupling (3/8" yellow)

310-D005
Disconnect Tool, Spring Lock Coupling (1/2" green)

412-038
Disconnect Tool, Spring Lock Coupling (5/8" black)

412-069
Disconnect Tool, Spring Lock Coupling (3/4" white)

Materials
Name Specification
Engine Oil - 5W-30 WSS-M2C153-G

Disconnect
WARNINGS:

Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions (100-
00 General Information, Description and Operation).

Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).
NOTE: Fuel supply line connectors are color coded white. Fuel return line connectors are
color coded red.
1. Release the fuel system pressure

Refer to: Fuel System Pressure Release (310-00

Fuel System - General Information, General
Procedures).
2. Special Tool(s): 310-137

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3. Special Tool(s): 310-040

4. Special Tool(s): 310-040

5.

6.

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7. Special Tool(s): 310-D004, 310-D005, 412-038,

412-069

8. Special Tool(s): 310-D004, 310-D005, 412-038,

412-069

9.

10. Special Tool(s): 310-D004, 310-D005, 412-038,

412-069

Connect

1. CAUTION: Only use the specified

material to lubricate the seals.
To connect, reverse the disconnect procedure.

Material: Engine Oil - 5W-30 (WSS-M2C153-G)

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Fuel System - General Information - Quick

S-MAX/Galaxy 2006.5 (02/2006-)
Release Coupling
Print

General Procedures
General Equipment
Flat-bladed screwdriver

Disconnect
WARNINGS:

Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions (100-
00 General Information, Description and Operation).

Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General
Information, Description and Operation).
NOTE: Fuel supply line connectors are color coded white. Fuel return line connectors are
color coded red.
1. Release the fuel system pressure

Refer to: Fuel System Pressure Release (310-00

Fuel System - General Information, General
Procedures).
2.

3.

4.

5.

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6.

7. General Equipment: Flat-bladed screwdriver

Connect
1. To connect, reverse the disconnect procedure.

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Fuel System - General Information - Fuel

System Pressure Check—2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE S-MAX/Galaxy 2006.5 (02/2006-)
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4
Print

General Procedures

Special Tool(s)
310-025
Fuel Pressure Gauge

310-025-18
Test Hose for 310-025

310-025-19A
Test Hose for 310-025

310-137
Disconnect Tool, Fuel Line

General Equipment
Flat-bladed screwdriver

WARNING: Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety
Precautions (100-00 General Information, Description and Operation).
1. Refer to: Fuel System Pressure Release (310-00
Fuel System - General Information, General
Procedures).

Vehicles with 2.0L engine

2. General Equipment: Flat-bladed screwdriver

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Vehicles with 2.3L engine

3. General Equipment: Flat-bladed screwdriver

All vehicles
4. Special Tool(s): 310-137

5. Install the Special Tool(s): 310-025, 310-025-18,

310-025-19A

6. Install the Special Tool(s): 310-025-18

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7. Install the Special Tool(s): 310-025-19A

8. Start the engine and allow it to idle.

9. Record the fuel system pressure at idle (3.8 +/-

0.2 bar maximum).

10. Stop the engine.

11. Refer to: Fuel System Pressure Release (310-00
Fuel System - General Information, General
Procedures).
12. Remove the Special Tool(s): 310-025-19A

13. Remove the Special Tool(s): 310-025-18

14.

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Vehicles with 2.0L engine

15.

Vehicles with 2.3L engine

16.

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Fuel System - General Information - Fuel

System Pressure Check—2.0L EcoBoost S-MAX/Galaxy 2006.5 (02/2006-)
SCTi (149kW/203PS) - MI4
Print

General Procedures

Special Tool(s)
310-025-18
Test Hose for 310-025

310-025-19A
Test Hose for 310-025

310-137
Disconnect Tool, Fuel Line

General Equipment
Adapter pressure vacuum transducer (C219)
Ford diagnostic equipment
GV2323 Connector
Pressure vacuum transducer (C407)

Activation
1. Refer to: Petrol and Petrol-Ethanol Fuel Systems
Health and Safety Precautions (100-00 General
Information, Description and Operation).
2. Refer to: Fuel System Pressure Release - 2.0L
EcoBoost SCTi (149kW/203PS) - MI4 (310-00
Fuel System - General Information, General
Procedures).
3.

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4. Special Tool(s): 310-137

5. Install the Special Tool(s): 310-025-18, 310-

025-19A

6. Install the Special Tool(s): 310-025-18, 310-

025-19A
General Equipment: GV2323 Connector

7. Connect the following items:

General Equipment: GV2323 Connector
General Equipment: Adapter pressure
vacuum transducer (C219)

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8. Connect the following items:

General Equipment: Pressure vacuum
transducer (C407)
General Equipment: Adapter pressure
vacuum transducer (C219)

9. Using the digital multi-meter function, measure

the fuel system pressure.

General Equipment: Ford diagnostic equipment

10. General Equipment: Ford diagnostic equipment

11. General Equipment: Ford diagnostic equipment

12. Refer to: Fuel System Pressure Release - 2.0L

EcoBoost SCTi (149kW/203PS) - MI4 (310-00
Fuel System - General Information, General
Procedures).
13. Disconnect the following items:
General Equipment: Pressure vacuum
transducer (C407)
General Equipment: Adapter pressure
vacuum transducer (C219)

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14. Disconnect the following items:

General Equipment: GV2323 Connector
General Equipment: Adapter pressure
vacuum transducer (C219)

15. Remove the Special Tool(s): 310-025-19A, 310-

025-18
General Equipment: GV2323 Connector

16. Remove the Special Tool(s): 310-025-19A, 310-

025-18

17.

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18.

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Fuel System - General Information - Fuel

System Pressure Check—2.5L Duratec S-MAX/Galaxy 2006.5 (02/2006-)
(162kW/220PS) - VI5
Print

General Procedures

General Equipment
Adapter pressure vacuum transducer (C219)
Ford diagnostic equipment
Pressure vacuum transducer (C407)
1. Refer to: Petrol and Petrol-Ethanol Fuel Systems
Health and Safety Precautions (100-00 General
Information, Description and Operation).
2. Refer to: Fuel System Pressure Release (310-00
Fuel System - General Information, General
Procedures).
3.
General Equipment: Adapter pressure
vacuum transducer (C219)

4. Connect the following items:

General Equipment: Adapter pressure
vacuum transducer (C219)
General Equipment: Pressure vacuum
transducer (C407)

5. Using the digital multi-meter function, measure

the fuel system pressure.

General Equipment: Ford diagnostic equipment

6. General Equipment: Ford diagnostic equipment

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7. General Equipment: Ford diagnostic equipment

8. Refer to: Fuel System Pressure Release (310-00

Fuel System - General Information, General
Procedures).
9. Disconnect the following items:
General Equipment: Adapter pressure
vacuum transducer (C219)
General Equipment: Pressure vacuum
transducer (C407)

10.
General Equipment: Adapter pressure
vacuum transducer (C219)

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Fuel System - General Information - Fuel

S-MAX/Galaxy 2006.5 (02/2006-)
System Pressure Release
Print

General Procedures

Release
1. Refer to: Petrol and Petrol-Ethanol Fuel Systems
Health and Safety Precautions (100-00 General
Information, Description and Operation).
2. Remove the fuel pump and sender unit fuse.
3. Start the engine and allow it to idle until the
engine stalls.
4. Crank the engine for approximately five seconds
to make sure that the fuel rail pressure is
released.
5. Install the fuel pump and sender unit fuse.

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Fuel System - General Information - Fuel

System Pressure Release—2.0L EcoBoost S-MAX/Galaxy 2006.5 (02/2006-)
SCTi (149kW/203PS) - MI4
Print

General Procedures

Pressure release
1. Refer to: Petrol and Petrol-Ethanol Fuel Systems
Health and Safety Precautions (100-00 General
Information, Description and Operation).
2.

3.

4. Start and run the engine at idle speed until the

engine stops.
5. Crank the engine for approximately 5 seconds to
release the fuel pressure.
6.

7.

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Fuel System - General Information - Fuel

System Pressure Release—2.0L EcoBoost S-MAX/Galaxy 2006.5 (02/2006-)
SCTi (149kW/203PS) - MI4
Print

General Procedures

Pressure release
1. Refer to: Petrol and Petrol-Ethanol Fuel Systems
Health and Safety Precautions (100-00 General
Information, Description and Operation).
2.

3.

4. Start and run the engine at idle speed until the

engine stops.
5. Crank the engine for approximately 5 seconds to
release the fuel pressure.
6.

7.

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Fuel System - General Information - Fuel

System Bleeding—1.8L Duratorq-TDCi S-MAX/Galaxy 2006.5 (02/2006-)
(Lynx) Diesel
Print

General Procedures

Special Tool(s)
310-110A
Hand Pressure Pump with Adapter Kit

310-110A-01
Adapter for 310-110A

1. Refer to: Quick Release Coupling (310-00 Fuel

System - General Information, General
Procedures).

2. Install the Special Tool(s): 310-110A, 310-

110A-01

3. Operate the hand pressure pump special tool

adapter until the fuel filter is full and the special
tool becomes firm.

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4. Refer to: Quick Release Coupling (310-00 Fuel

System - General Information, General
Procedures).

5. CAUTION: The starter motor operation

must not exceed 10 seconds at a time. After
10 seconds turn the ignition switch to
position 0 and allow the starter motor to cool
for 30 seconds before operating the starter
motor again.
Start the engine and allow it to idle until it
reaches normal operating temperature.
6. Switch off the engine.
7. Remove the Special Tool(s): 310-110A, 310-
110A-01

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Fuel System - General Information - Fuel

System Bleeding—2.0L Duratorq-TDCi S-MAX/Galaxy 2006.5 (02/2006-)
(DW) Diesel
Print

General Procedures

Special Tool(s)
310-025-19A
Test Hose for 310-025

310-042
Connector for 310-025

310-110A
Hand Pressure Pump with Adapter Kit

1. Refer to: Diesel Fuel System Health and Safety

Precautions (100-00, Description and Operation).
2.

3. Special
Tool(s):
310-025-
19A, 310-
110A,
310-042

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4. Operate the hand pressure pump special tool

adapter until fuel is visible in the clear plastic
tube.

Special Tool(s): 310-025-19A, 310-110A, 310-

042

5. CAUTION: The starter motor operation

must not exceed 10 seconds at a time. After
10 seconds turn the ignition switch to
position 0 and allow the starter motor to cool
for 30 seconds before operating the starter
motor again.
Start the engine and allow it to idle until it
reaches normal operating temperature.
6. Switch off the engine.
7. Remove the Special Tool(s): 310-025-19A, 310-
025-19A, 310-110A
8.

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Fuel System - General Information - Fuel

System Bleeding—2.2L Duratorq-TDCi S-MAX/Galaxy 2006.5 (02/2006-)
(DW) Diesel
Print

General Procedures

Special Tool(s)
310-110A
Hand Pressure Pump with Adapter Kit

1.

2. WARNING: Be prepared to collect

escaping fuel.

CAUTION: Extreme cleanliness must be

exercised when handling these components.

3. WARNING: Be prepared to collect

escaping fuel.
Operate the hand pressure pump special tool
adapter until the fuel filter is full and the special
tool becomes firm.

Special Tool(s): 310-110A

4.

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5. Torque: 10 Nm

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