Ford Galaxy / Ford S-MAX. Manual — part 379

9. Material:

Silicone Sealant LB (WSE-M4G323-A4 /

2U7J-M4G323-AA)

10. Material:

Thread Locking MS (WSK-M2G349-A7 /

2U7J-M2G349-AA)

11.

NOTE: Make sure that a new component is
installed.

Discard the blanking plugs.

Torque:

Fuel pump high-pressure fuel supply line
union 25 Nm
Fuel rail high-pressure fuel supply line
union 38 Nm
Fuel pump bracket bolts 23 Nm

12. Remove the lint-free material.

13. Install the timing belt.

Refer to:

Timing Belt

(303-01E Engine - 1.8L

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

14. Install a new fuel filter element.

Refer to:

Fuel Filter Element

(310-01B Fuel Tank

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

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 -
Specifications

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

Print

Torque Specifications

a) Refer to the relevant procedure in this section.

Item

Nm

lb-ft

lb-in

Windshield wiper arm retaining nuts

15

11

-

Fuel filter crash protection shield retaining bolts

9

-

80

Fuel filter support bracket retaining bolts

9

-

80

High-pressure fuel injection supply pipe unions

23

17

-

Fuel injection supply manifold retaining bolts

22

16

-

Intake manifold retaining bolts

9

-

80

Timing belt upper cover retaining bolts

7

-

62

Fuel injector retaining bracket nuts

a

-

-

Fuel pump retaining bolts

20

15

-

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-)

Print

Description and Operation

General Overview

Description

Fuel filter housing

Fuel injector(s)

Fuel pump

Fuel metering valve

Fuel pressure regulator

High-pressure fuel supply line(s)

Fuel rail

Fuel rail pressure (FRP) sensor

Intake air shutoff throttle

A Siemens common rail diesel injection system is used on the 2.0L Duratorq TDCi (DW10)

Item

1

2

3

4

5

6

7

8

9

Part Number

-

-

-

-

-

-

-

-

-

engine.

Within the fuel pump is an integral fuel transfer pump which delivers the fuel from the fuel
tank to the fuel pump.

A fuel metering valve is located in the feed port to the high-pressure chamber of the fuel
pump. The fuel metering valve varies the quantity of fuel supplied to the fuel pump
elements, in accordance with driving conditions.

At high-pressure, the fuel is sent to the fuel rail and then to the fuel injectors ready for fuel
injection. Depending on engine operating conditions, the fuel injection pressure varies
between approximately. 350 bar and 1650 bar.

Fuel pressure is measured using a FRP sensor on the fuel rail. The FRP sensor converts the
fuel system pressure into a voltage signal. This voltage signal acts as an input signal to the
powertrain control module (PCM) for calculation of the correct fuel injection quantity.

The PCM calculates the time of fuel injection and the fuel injection quantity depending on
various input variables.

The specified quantity of fuel is injected into the respective combustion chamber through
the piezo-electrically actuated fuel injectors. In doing so, a pre-injection and a main
injection occur each time.

The excess fuel is returned to the fuel tank through the fuel return line.

The fuel pressure regulator on the high-pressure outlet of the fuel pump regulates the fuel
pressure and thereby also the pressure within the fuel rail.

Fuel pump

Description

High-pressure outlet union

Fuel pump fuel supply union

Fuel metering valve

Fuel return union

Fuel pressure regulator

The fuel pump is attached to the cylinder head on the transmission side and is driven
directly by the exhaust camshaft through a drive flange.

Item

1

2

3

4

5

Part Number

-

-

-

-

-