Ford Galaxy / Ford S-MAX. Manual — part 380

The fuel pump has three pump elements, each offset from each other by 120 degrees.

The fuel transfer pump is incorporated into the fuel pump and is located on the drive
flange. The fuel transfer pump is a vane type pump.

The fuel metering valve is located in the feed port between the high-pressure pump
elements and the fuel transfer pump. It is controlled by the PCM using pulse width
modulation.

The high-pressure outlets of the three high-pressure pump elements are grouped together
in a high-pressure connection.

The fuel pressure regulator is located on the high-pressure outlet to the fuel rail. The fuel
pressure regulator operates electromagnetically and is actuated by the PCM.

Fuel rail

Description

Fuel rail pressure (FRP) sensor

The fuel rail is made from forged steel and is attached directly to the cylinder block.

The high-pressure fuel is delivered through one high-pressure fuel supply line from the fuel
pump to the fuel rail.

From the fuel rail, the high-pressure fuel is directed to four more high-pressure fuel supply
lines for fuel injection delivery by the fuel injectors.

Fuel filter

Description

Fuel filter fuel supply union

Fuel pump fuel supply union

Electric fuel heater

Drain plug

The fuel filter is located above the fuel rail and is attached to the cylinder head by means of
a bracket.

The fuel filter has an electric fuel heater which is located centrally on the fuel filter between
the supply connection and the drain connection.

The fuel filter forms a single component with the housing and can only be renewed as a

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complete unit.

The fuel filter also has a drain plug. This must be drained regularly in accordance with
maintenance instructions.

Fuel injectors

Description

High-pressure fuel supply union

Electrical connector

Fuel injector clamp

Copper sealing washer

Plastic guide bush

Fuel injector fuel return port

The fuel injectors are located centrally on the cylinder head upper section and are attached
by means of clamps.

The guide bushes in the cylinder head lower section and the plastic guide bushes on the
fuel injectors make sure that they are centred properly.

The fuel injectors are sealed off from the combustion chamber by means of a copper
sealing washer located between the fuel injector and the cylinder head. A new sealing
washer must be installed when servicing the fuel injectors.

The fuel return lines are attached to the top of the fuel injector and are connected in series.

Intake air shutoff throttle

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Description

Manifold absolute pressure (MAP) sensor

Intake air temperature (IAT) sensor

Intake air shutoff throttle

The intake air shutoff throttle is located on the intake air side of the intake manifold.

The intake air shutoff throttle is electronically controlled by the PCM and is used to control
vehicle characteristics while the engine is switched off. This will also prevent the engine
being continuously fuelled by the engine oil after the ignition key has been turned to
position 0. This is achieved by reducing the intake air through the intake manifold.

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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 Charging and Controls

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

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Diagnosis and Testing

General Equipment

Principles of Operation

The 2.0L DW10 engine uses a second generation Siemens common rail fuel injection
system. The systems main components consist of a fuel pump, fuel rail, electrically
operated fuel injectors, a fuel temperature sensor and a fuel rail pressure sensor.

Fuel Pump

Description

Fuel pump fuel intake

Fuel pump high-pressure fuel outlet

Fuel metering valve

High-pressure fuel pump chamber

Fuel pump fuel return outlet

High pressure fuel control valve

The fuel pump consists of a transfer pump and a high-pressure fuel delivery pump. The
transfer pump draws fuel from the fuel tank through the fuel filter and delivers the fuel to
the three high-pressure fuel pump chambers through a fuel metering valve. The fuel
metering valve controls the quantity of fuel that is allowed to enter the high-pressure fuel
pump chambers. Excess fuel volume developed by the transfer pump is returned to the fuel
tank. The fuel metering valve is controlled by the powertrain control module (PCM) using a
pulse-width modulated signal. The high-pressure fuel pump outlet pressure is controlled by
an electronic fuel control valve which is also controlled by the PCM.

Fuel Rail

Worldwide Diagnostic System (WDS)

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