Ford Galaxy / Ford S-MAX. Manual — part 381

Description

Fuel rail

Fuel rail pressure (FRP) sensor

The fuel rail function is to supply a reservoir of fuel to all four fuel injectors with no
variations in fuel pressure for any one fuel injector. The fuel rail acts as a pulse damper
eliminating surges in fuel pressure. Attached to the fuel rail is a FRP sensor, which monitors
the fuel pressure at the fuel injectors. The FRP sensor develops a pressure conscious
variable resistance which provides a controlled variable voltage signal to the PCM.

Fuel Injectors

Description

High-pressure fuel intake

Piezoelectric actuator

Fuel injector control valve

Fuel injector fuel return

The fuel injectors have a Piezoelectric actuator. The advantages of using Piezoelectric
instead of traditional solenoid actuators are the reduction in reaction switching times and
the lower switching currents. Both of which improve the control and therefore the efficiency
of the fuel injector. During manufacture, the fuel injectors are graded according to their

Item

1

2

Item

1

2

3

4

Part Number

-

-

Part Number

-

-

-

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flow characteristics into one of three grades. The grade is printed on the top of the fuel
injector and can be the number 4, 5, or 6. All four fuel injectors must be of a matching
grade for any one engine application. The grade value is used by the PCM to adjust the fuel
injector injection signal to achieve optimum efficiency. The fuel injectors are designed to
allow a quantity of fuel to return to the fuel tank. The returned fuel is developed during the
opening cycle of the fuel injector control valve. This returned fuel is used to lubricate the
fuel injector moving components and is essential to the operation of the fuel injector. This
lubricating fuel is returned to the fuel tank through the fuel injector fuel return line. Only by
accurate measurement, at precise engine conditions, can the volumes of fuel from the fuel
injector fuel return be used to diagnose concerns with the fuel charging control system.

Fuel Temperature Sensor

Description

Fuel injector fuel return line

Fuel pump fuel return line

Fuel temperature sensor to fuel tank fuel return line

Fuel temperature sensor

The fuel temperature sensor is fitted into the fuel pump to fuel tank fuel return line. The
temperature sensor monitors the temperature of the fuel returning to the fuel tank from the
fuel pump and the fuel injectors. The fuel temperature sensor housing acts as a venturi.
The venturi assists with the fuel return from the fuel injectors by creating a pressure
reduction in the fuel injector fuel return line.

Inspection and Verification

WARNINGS:

REFER to:

Diesel Fuel System Health and Safety Precautions

(100-00 General

Information, Description and Operation).

This procedure involves fuel handling. Be prepared for fuel spillage at all times.

Failure to follow this instruction may result in personal injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances

and fine clearances. It is therefore essential that absolute cleanliness is observed when
working with these components. Always fit blanking plugs to any open orifices or lines.
NOTE: As well as carrying out its normal function the glow plug indicator also acts as an
engine check lamp which will flash continuously when a hard diagnostic trouble code
(DTC) is detected by the powertrain control module (PCM). Soft DTCs are also stored by
the PCM but will only be known if the system is checked for DTCs using the WDS.
NOTE: If a DTC is detected, all DTCs must be cleared after the concern is rectified. Failure
to clear all DTCs may cause driveability concerns.
NOTE: If the fuel level in the fuel tank drops below approximately four liters, rough
running will occur. This is to signal to the driver that the vehicle requires refuelling in
order to prevent the fuel system from running dry.

1. 1. Verify the customer concern.

Item

1

2

3

4

Part Number

-

-

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2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step.

4. 4. If the cause is not visually evident, verify the symptom and refer to the WDS to

retrieve the diagnostic trouble codes (DTCs).

5. 5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to

continue diagnostics.

Symptom Chart

Mechanical

Electrical

Fuel leak(s)

Fuse(s)

Fuel filter

Relay(s)

Air cleaner element

Wiring harness

Vacuum line(s)/vacuum connections

Electrical connector(s)

Hose(s)/hose connections

Sensor(s)

Tube(s)/tube connections
Contaminated fuel
Fuel supply line(s)
Fuel return line(s)
High-pressure fuel supply line(s)
Fuel injectors
Fuel rail
Fuel pump

Symptom

Possible Sources

Action

Engine does not
crank and passive
anti-theft system
(PATS) LED is
flashing

PATS system fault

detected.

*

REFER to:

Anti-Theft - Passive

(419-01B Anti-

Theft - Passive, Diagnosis and Testing).

*

Engine does not
crank and glow
plug indicator is
flashing

DTC detected.

*

REFER to the WDS.

*

Engine does not
crank

Starting system.

*

REFER to:

Starting System

(303-06E Starting

System - 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).

*

Engine cranks but
does not start and
glow plug indicator
is flashing

DTC detected.

*

REFER to the WDS.

*

Engine cranks but
does not start

Low fuel tank fuel

level.

*

CHECK the fuel tank fuel level is greater than

four liters. If the fuel tank fuel level is less then
four liters, FILL with fuel.

*

Fuel filter blocked.

*

INSTALL a new 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).

Fuel lines damaged or

blocked.

*

REFER to:

Fuel System - 1.8L Duratorq-TDCi

(Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel

(310-00 Fuel System - General Information,
Diagnosis and Testing).

*

Air ingress into the

fuel lines.

*

REFER to:

Fuel System - 1.8L Duratorq-TDCi

(Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel

(310-00 Fuel System - General Information,
Diagnosis and Testing).

*

Glow plugs.

*

REFER to the WDS.

*

Incorrect valve

timing.

*

CHECK the valve timing.

REFER to:

Timing Belt

(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).

*

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).

*

Crankshaft position

(CKP) sensor.

*

REFER to the WDS.

*

Camshaft position

(CMP) sensor.

*

REFER to the WDS.

*

Engine coolant

temperature (ECT)
sensor.

*

REFER to the WDS.

*

PCM.

*

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 injector(s).

*

REFER to the WDS.

*

Poor starting and
glow plug indicator
is flashing

DTC detected.

*

REFER to the WDS.

*

Poor starting

Low fuel tank fuel

level.

*

CHECK the fuel tank fuel level is greater than

four liters. If the fuel tank fuel level is less then
four liters, FILL with fuel.

*

Fuel filter blocked.

*

INSTALL a new fuel filter element.

REFER to:

Fuel Filter Element

(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).

*

Air cleaner element

blocked.

*

INSTALL a new air cleaner element.

*

Glow plugs.

*

REFER to the WDS.

*

Fuel system leak.

*

CHECK the system for fuel leak(s). REPAIR the

system as necessary.

*

Air ingress into the

fuel lines.

*

REFER to:

Fuel System - 1.8L Duratorq-TDCi

(Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel

(310-00 Fuel System - General Information,

*