Ford Galaxy / Ford S-MAX. Manual — part 371

Description

Fuel rail

Fuel rail pressure (FRP) sensor

The fuel rail provides a reservoir of high-pressure fuel which is available for all four fuel
injectors. The fuel rail also provides pulse damping of the pressure surges in high-pressure
fuel system. Attached to the fuel rail is a FRP sensor. The FRP sensor monitors the fuel
pressure in the fuel rail. The FRP sensor provides a controlled variable voltage signal to the
PCM, which is converted into a pressure signal.

Fuel injectors

Description

Fuel injector electrical connector

Fuel injector

Item

1

2

Item

1

2

Part Number

-

-

Part Number

-

-

-

High-pressure fuel supply port

Sealing washer

Fuel injector retaining clamp bolt

Fuel injector retaining clamp

Fuel injector fuel return line retaining clip

Description

High-pressure fuel supply port

Fuel injector fuel return port

Fuel injector electrical connector

Piezoelectric actuator

Piezoelectric actuated valve

needle valve

Injection control valve

Fuel injection valve

High-pressure fuel chamber

Fuel injector fuel delivery holes

The fuel injectors have a Piezoelectric actuator. The advantages of using Piezoelectric
instead of traditional solenoid actuators are the reduction in reaction switching times and
the lower switching currents. Both of which improve the control and therefore the efficiency
of the fuel injector.

Fuel temperature sensor

3

4

5

6

7

Item

1

2

3

4

5

6

7

8

9

10

-

-

-

-

Part Number

-

-

-

-

-

-

-

-

-

-

Description

Fuel injector fuel return line

Fuel temperature sensor

Fuel pump fuel return line

Fuel tank fuel return line union

The fuel temperature sensor is installed into the fuel injector to fuel tank fuel return line.
The temperature sensor monitors the temperature of the fuel returning to the fuel tank
from the fuel injectors and sends a signal to the PCM.

Inspection and Verification

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.

Failure to follow this instruction may result in personal injury.

CAUTION: 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 fit blanking plugs to any open orifices or lines.
NOTE: As well as carrying out its normal function the glow plug indicator also acts as an
engine check lamp which will flash continuously when a hard diagnostic trouble code
(DTC) is detected by the powertrain control module (PCM). Soft DTCs are also stored by
the PCM but will only be known if the system is checked for DTCs using Ford approved
diagnostic tool.
NOTE: If a DTC is detected, all DTCs must be cleared after the concern is rectified. Failure
to clear all DTCs may cause driveability concerns.
NOTE: If the fuel level in the fuel tank drops below approximately four litres, rough
running will occur. This is to signal to the driver that the vehicle requires refuelling in
order to prevent the fuel system from running dry.

1. 1. Verify the customer concern.

Item

1

2

3

4

Part Number

-

-

-

-

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

Visual Inspection Chart

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 to retrieve the diagnostic trouble codes (DTCs).

5. 5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart

below to continue diagnostics.

Symptom Chart

Mechanical

Electrical

Fuel leak(s)

Fuse(s)

Fuel filter

Relay(s)

Air cleaner element

Wiring harness

Vacuum line(s)/vacuum connections

Electrical connector(s)

Hose(s)/hose connections

Sensor(s)

Tube(s)/tube connections
Contaminated fuel
Fuel supply line(s)
Fuel return line(s)
High-pressure fuel supply line(s)
Fuel injectors
Fuel rail
Fuel pump

Symptom

Possible Sources

Action

Engine does not
crank and passive
anti-theft system
(PATS) LED is
flashing

PATS system fault

detected.

*

REFER to:

Anti-Theft - Passive

(419-01B Anti-

Theft - Passive, Diagnosis and Testing).

*

Engine does not
crank and glow
plug indicator is
flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Engine does not
crank

Starting system.

*

REFER to:

Starting System

(303-06D Starting

System - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx,
Diagnosis and Testing).

*

Engine cranks but
does not start and
glow plug indicator
is flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Engine cranks but
does not start

Low fuel tank fuel

level.

*

CHECK the fuel tank fuel level is greater than

four litres. If the fuel tank fuel level is less then
four litres, FILL with fuel.

*

Fuel filter blocked.

*

INSTALL a new fuel filter.

REFER to:

Fuel Filter

(310-01A Fuel Tank and

Lines - 2.0L EcoBoost SCTi (149kW/203PS) -
MI4/2.0L Duratec-HE (107kW/145PS) - MI4/2.0L
Duratec-HE Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4/2.5L Duratec
(162kW/220PS) - VI5, Removal and

*