Ford Galaxy / Ford S-MAX. Manual — part 606

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 - Fuel Tank
and Lines—2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4, Vehicles With:
Ethanol Capability - Overview

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

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Description and Operation

The fuel tank and fuel lines are the same as those in vehicles for petrol operation.

Properties of ethanol E85

CAUTION: Fuels containing ethanol have a corrosive effect on other materials such as

plastic, paint and metal.

Ethanol E85:

is described by the standard ASTM D5798 (Ed75-Ed85)
contains approximately 85% ethanol and 15% petrol with 95 octane rating in "summer
quality"
contains approximately 75% ethanol and 25% petrol with 95 octane rating in "winter
quality"
has an antiknock resistance of approx. 104

RON (research octane number)

supplies around 66% of the energy content of petrol
causes around 70-80% less carbon dioxide emissions
the ethanol share is free from sulphur and odors and contains no carcinogenic
compounds such as benzene

Fuel Tank and Lines

CAUTION: If another fuel type is used after emptying the fuel tank, at least 10 liters

more must be added in order to start fuel type determination and adaptation.

The fuel tank and rust-free fuel lines are the same for petrol vehicles as for vehicles
operated with ethanol. To achieve this, the components optimized for ethanol operation
have been applied to the entire product range.

Fuel pump driver module

The fuel pump driver module must not be dismantled and must be replaced as a whole.

The fuel pump driver module is different for petrol vehicles and for vehicles operated with
ethanol, and must not be interchanged.

Description

Fuel pump driver module - petrol vehicle

Item

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Fuel pump driver module - ethanol vehicle

Encapsulated connector

The fuel pump module for ethanol operation looks very similar to the fuel pump module for
petrol vehicles. The difference is in the fuel pump connector. This is encapsulated due to the
higher conductivity of the ethanol share.

Description

Fuel level sensor

Resistor board

The resistor board of the fuel level sensor is supplied with alternating voltage instead of
direct voltage. This prevents electrolysis and the deposit of particles. The alternating
voltage is generated by a

DC (direct current)

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AC (alternating current)

converter. The

DC

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AC

converter is integrated in the wiring harness or the

GEM (generic electronic module)

depending on the construction period. It converts the direct voltage into an alternating
voltage with a frequency of 170 Hz. The course of the alternating voltage corresponds to a
rectangular impulse.

Both fuel pump driver units have different resistance tracks for the fuel level sensor.

Another difference is that the fuel pump driver unit for ethanol operation is manufactured
from ethanol-resistant materials.

The fuel level sensor is used during fuel type determination.
Refer to:

Electronic Engine Controls - Vehicles With: Ethanol Capability

(303-14A Electronic

Engine Controls - 2.0L Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4, Description and Operation).

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3

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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 - Fuel Tank
and Lines—2.5L Duratec (162kW/220PS)
- VI5

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

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Description and Operation

General overview

Description

Fuel rail

Evaporative emission canister to evaporative emission canister purge
valve line

Evaporative emission canister purge valve

Fuel supply line

Evaporative emission canister purge to intake manifold vacuum line

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Description

Fuel tank filler pipe

Fuel tank filler pipe cap

Fill limit vent valve

Evaporative emission canister

Evaporative emission canister dust filter

Fuel tank support strap(s)

Fuel tank vent valve(s)

Fuel pump driver module (FPDM)

Fuel pump and sender unit (including fuel filter)

Fuel supply line

Evaporative emission canister to evaporative emission canister purge
valve line

Fuel tank

The fuel tank holds approximately 70 liters of usable fuel and is of a plastic construction. It
is retained to the vehicle by means of two steel support straps, the fuel tank supports
straps are secured by four retaining bolts onto the underside of the vehicle chassis.

Fuel tank ventilation is achieved by two fuel tank vent valves venting through a fuel limit
vent valve and into an evaporative emission canister which absorbs the fuel vapor. The fuel
tank vent valve will prevent fuel loss from the fuel tank if the vehicle becomes inverted.

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