Ford Galaxy / Ford S-MAX. Manual — part 388

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 Pump

S-MAX/Galaxy 2006.5 (02/2006

Removal and Installation

Removal

WARNING: Refer to:

Diesel Fuel System Health and Safety Precautions

(100-00 General

Information, Description and Operation).
NOTE: Removal steps in this procedure may contain installation details.

1. Remove the exhaust manifold to exhaust gas recirculation

(EGR) valve tube.

Refer to:

Exhaust Manifold to Exhaust Gas Recirculation (EGR)

Valve Tube

(303-08D Engine Emission Control - 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).

2. Remove the air cleaner.

Refer to:

Air Cleaner

(303-12E Intake Air Distribution and

Filtering - 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-
(103kW/140PS) - DW/2.0L Duratorq-TDCi (118kW/160PS)
DW, Emission Requirements: Stage IV/Stage V, Removal and
Installation).

3.

4. Clean the fuel pump, fuel rail, high-pressure fuel supply line

and surrounding areas.

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).

5.

CAUTIONS:

Make sure

that the fuel line
remains in
contact at both
ends until both
unions nuts have
been unscrewed

and the area
around the joints
thoroughly
cleaned.

Vacuum any

foreign material
from the fuel
pump and fuel
rail unions before
sealing the
unions with
blanking caps.

Make sure

that all openings
are sealed. Use
new blanking
caps.

2. Refer to:

Quick Release
Coupling

(310
System
General
Information,
General
Procedures).

5. Refer to:

Quick Release
Coupling

(310
System
General
Information,
General
Procedures).

8.

NOTE:
Make sure
that new
components
are
installed.

Discard the
high
fuel supply
line.

9.

NOTE: The
gasket is to
be reused
unless
damaged.

Torque:
Nm

6. Remove and discard 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)

Installation

DW, Emission Requirements: Stage IV, Removal and
Installation).

1.

NOTE:

To install, reverse the removal procedure.

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 - Intake Air Shutoff
Throttle

S-MAX/Galaxy 2006.5 (02/2006

Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

Installation

1.

2.

CAUTION:

Make sure
that the inside
of the pipe
ends are clean
and free of oil
residue.
NOTE: The
seal is to be
reused unless
damaged.

1. Torque:

Nm

2. Torque:

Nm

3. Torque:

Nm

1. To install, reverse the removal procedure.