Ford Galaxy / Ford S-MAX. Manual — part 385

Requirements: Stage IV, Removal and
Installation).

Turbocharger.

*

REFER to: Turbocharger (303-04G Fuel

Charging and Controls - Turbocharger - 2.0L
Duratorq-TDCi (DW) Diesel, Diagnosis and
Testing).

*

Slipping clutch (If

equipped).

*

REFER to: Manual Transaxle and Clutch (308-

00 Manual Transmission/Transaxle and Clutch -
General Information, Diagnosis and Testing).

*

Low cylinder

compression.

*

REFER to:

Engine

(303-01F Engine - 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).

*

ECT sensor.

*

REFER to the WDS.

*

MAF sensor.

*

REFER to the WDS.

*

MAP sensor.

*

REFER to the WDS.

*

Fuel injector(s).

*

REFER to the WDS.

*

Intake air shut-off

throttle.

*

CHECK the intake air shut-off throttle butterfly

for obstructions and correct operation.

REFER to the WDS.

*

*

Intake air shut-off

throttle vacuum
control solenoid.

*

CHECK the intake air shut-off throttle vacuum

control solenoid vacuum lines for kinks or
restrictions.

REFER to the WDS.

*

*

Engine cuts out
during hard
acceleration

CMP sensor.

*

REFER to the WDS.

*

CKP sensor.

*

REFER to the WDS.

*

FRP sensor.

*

REFER to the WDS.

*

Fuel pump fuel

pressure regulator.

*

REFER to the WDS.

*

Fuel pump.

*

REFER to the WDS.

*

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 -
Fuel Injection Component Cleaning

S-MAX/Galaxy 2006.5 (02/2006-)

Print

General Procedures

Materials

General Equipment

CAUTION: Use lint free cloth.

Name

Specification

Brake Cleaner 3U7J-2C410-AA

Pneumatic vacuum gun

1. Refer to:

Solvents, Sealants and Adhesives

(100-

00 General Information, Description and
Operation).
Refer to:

Diesel Fuel System Health and Safety

Precautions

(100-00 General Information,

Description and Operation).

2.

3.

CAUTION: Use lint free cloth.

Material:

Brake Cleaner (3U7J-2C410-AA)

4. Using a new brush that will not lose its bristles,

brush a suitable evaporative cleaning agent onto
the components being removed and onto the
surrounding area.

5. Remove all traces of evaporative cleaning agent

and foreign material.

General Equipment:

Pneumatic vacuum gun

6. Dispose of any unused evaporative cleaning

agent and the brush after completing the repair.

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 - Fuel Rail

S-MAX/Galaxy 2006.5 (02/2006

Removal and Installation

Removal

WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature

is at ambient temperature.
NOTE: Removal steps in this procedure may contain installation details.

1. Refer to:

Diesel Fuel System Health and Safety Precautions

(100-00 General Information, Description and Operation).

2. Remove the intake manifold.

Refer to:

Intake Manifold

(303-01F Engine - 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).

3. Remove the fuel filter.

Refer to:

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).

4. Torque: 9 Nm

5. Vacuum foreign material from the high-pressure fuel supply

line unions and component threads.

Refer to:

Fuel Injection Component Cleaning

(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, General Procedures).

6.