Ford Galaxy / Ford S-MAX. Manual — part 619

Description

Fuel tank locking ring

Fuel level sensor

Fuel level sensor seal

Fuel tank level sensor float and arm

The fuel level sensor is located in the top of the fuel tank and retained by a re-usable fuel
tank locking ring. The fuel level sensor seal must not be re-used once removed from the
fuel tank.

The fuel level sensor is equipped with a fuel tank sender unit. The fuel tank sender unit
consists of a mechanical float and a potentiometer. The potentiometer measures the fuel
level using a float and communicates directly with the fuel gauge in the instrument cluster
informing the driver the amount of fuel that is currently in the fuel tank.

CAUTION: Make sure that the fuel tank level sensor float and arm are not damaged

during the installation.
NOTE: Make sure that the installation marks are aligned.

The fuel tank must be completely removed from the vehicle before the fuel level sensor unit
can be removed.
For additional information, refer to:

Fuel Tank

(310-01B Fuel Tank and Lines - 1.8L

Duratorq-TDCi (74kW/100PS) - Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx, Removal
and Installation).

Installation of a new fuel level sensor may not solve fuel indication issues which may occur
during the vehicles life time.

Item

1

2

3

4

Part Number

-

-

-

-

Fuel filter - vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine

Description

Fuel filter top shield

Fuel filter bleed screw

Fuel filter housing

Fuel filter drain screw

Fuel filter fuel supply line

Fuel filter to fuel pump fuel supply line

The 1.8L Duratorq-TDCi (Kent) diesel engine fuel filter is located above the transmission
and is attached to the cylinder head by means of a fuel filter retaining bracket. The fuel
filter has an electric fuel heater which is located next to the fuel pump fuel supply line.

When the fuel temperature is below 15ºC, a valve inside the fuel filter opens, allowing fuel
which is pre-heated by the fuel pump to be recirculated back through the fuel filter to the
fuel pump. This aids engine performance during warm-up.

Fuel is delivered through the fuel supply line to the fuel filter. The fuel filter cleans the fuel
of water and contaminants. Unused fuel is returned to the fuel tank through the fuel pump
fuel return line.

When a new fuel filter has been installed it must be bled using a hand pressure pump. Make
sure that the arrows indicating the direction of fuel flow is pointing towards the fuel filter.
For additional information, refer to:

Fuel Filter

(310-01B Fuel Tank and Lines - 1.8L

Item

1

2

3

4

5

6

Part Number

-

-

-

-

-

-

Duratorq-TDCi (74kW/100PS) - Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx, Removal
and Installation).

Fuel filter - vehicles with 2.0L Duratorq-TDCi (DW) diesel engine

Description

Fuel filter crash protection top shield

Fuel filter bleed screw

Fuel filter housing

Water in fuel sensor

Fuel filter to fuel pump fuel supply line union

Fuel filter drain screw

Fuel filter fuel supply line union

The 2.0L Duratorq-TDCi (DW) diesel engine fuel filter is located above the generator and is
attached to the cylinder head by means of a fuel filter retaining bracket, a fuel filter splash
shield and a fuel filter crash protection shield are mounted to the retaining bracket. The fuel
filter has an electric fuel heater which is located next to the fuel filter inlet pipe.

When the temperature is below 15ºC, a valve inside the fuel filter opens allowing fuel which
is pre-heated by the fuel pump to be recirculated back through the fuel filter to the fuel
pump. This aids engine performance during warm up.

Fuel is delivered through the fuel supply lines to the fuel filter. The fuel filter cleans the fuel
of water and contaminants. Unused fuel is returned to the fuel tank through the fuel pump

Item

1

2

3

4

5

6

7

Part Number

-

-

-

-

-

-

-

return line.

The fuel filter is also equipped with a water-in-fuel sensor which is located at the base of
the fuel filter housing. This sensor measures the amount of water which has collected in the
fuel filter element. If the quantity of water present is greater than 90 ml then a warning
indicator located on the instrument cluster is illuminated and the fuel filter element should
then be drained of water.

When a new fuel filter has been installed it must be bled using a hand pressure pump. Make
sure that the arrows indicating the direction of fuel flow is pointing towards the fuel filter.
For additional information, 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).

Fuel tank vent valve

Description

Fuel tank vent valve

Fuel tank ventilation is achieved by a fuel tank vent valve and the fuel limit vent valve,
which is installed into the top of the fuel tank and will prevent fuel loss from the fuel tank if
the vehicle becomes inverted.

Fill limit vent valve

Description

Fill limit vent valve

The fill limit vent valve is an intermediate ventilation valve between the fuel tank vent valve
and the atmosphere.

The fill limit vent valve allows the fuel tank to be filled to its maximum, by expelling the air
within the fuel tank to atmosphere.

The fill limit vent valve also acts as a fuel tank breather with a dust filter. If this dust filter
becomes blocked or restricted during the vehicle's lifetime, problems will be experienced
with draining the fuel tank. Also there could be a possibility of fuel tank deformation if the
dust filter is blocked.

Item

1

Item

1

Part Number

-

Part Number

-