Ford Galaxy / Ford S-MAX. Manual — part 618

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 - Fuel Tank and
Lines

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

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Description and Operation

General overview

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine

Description

Fuel filter fuel supply line

Fuel return line

Fuel filter

Fuel injector fuel return lines

Fuel pump fuel return line

Fuel filter to fuel pump fuel supply line

Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine

Item

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6

Part Number

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Description

Fuel return line

Fuel filter fuel supply line

Fuel pump

Fuel pump fuel return line

Fuel pump fuel supply line

Fuel injector fuel return line

Fuel filter

All vehicles

Item

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7

Part Number

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Description

Fuel tank filler pipe

Fuel tank filler pipe cap

Fill limit vent valve dust filter

Fuel tank support strap(s)

Fill limit vent valve

Fuel level sensor

Fuel return line

Fuel supply line

Fuel tank vent valve

Fuel tank

The fuel tank holds approximately 70 liters of usable fuel and is of a plastic construction. It
is retained to the vehicle by means of two steel support straps, the fuel tank supports
straps are secured by four retaining bolts onto the underside of the vehicle chassis.

Fuel tank ventilation is achieved by one fuel tank vent valve and a fill limit vent valve
ventilating directly to atmosphere. The fuel tank vent valve will prevent fuel loss from the
fuel tank if the vehicle becomes inverted.

Fuel lines

Item

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10

Part Number

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Description

Fuel line cover

Fuel return line

Fuel supply line

The fuel supply and return lines are constructed from PA nylon tubes and are retained by
clips which are made of plastic. The fuel lines are protected under the vehicle by a plastic
cover, which is clipped to welded studs.

Within the engine compartment, some fuel lines are produced from steel for improved
robustness.

The fuel supply and return lines are separated into three sections. The fuel line connections
have quick release couplings at each end to secure them to the fuel tank lines and front end
fuel lines.
For additional information, refer to:

Quick Release Coupling

(310-00 Fuel System - General

Information, General Procedures).

Fuel level sensor

Item

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2

3

Part Number

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