Ford Galaxy / Ford S-MAX. Manual — part 596

Pinpoint Tests

Fuel filler nozzle
shuts off
prematurely

Fuel tank ventilation

hose or pipe
blocked.

Fuel tank ventilation

hose or pipe
collapsed.

*

*

CHECK the fuel tank ventilation hose for

obstruction or damage. INSTALL a new fuel tank
ventilation pipe.

*

Fuel tank filler pipe

or hose blocked.

Fuel tank filler pipe

or hose collapsed.

*

*

CHECK the fuel tank filler pipe or hose for

obstruction or damage. INSTALL a new fuel tank
filler pipe.

*

Fuel gauge

indication.

*

CHECK the fuel level in the fuel tank. CHECK the

fuel indication system. For additional information,
REFER to:

Instrument Cluster

(413-01 Instrument

Cluster, Diagnosis and Testing).

*

Fuel filler nozzle at

fuel filling station not
functioning correctly.

*

VERIFY condition by using a known good fuel filler

nozzle.

*

Fuel loss after
nozzle shutoff or
during refilling

Fuel tank filler pipe

or hose leaking.

*

CHECK the fuel tank filler pipe and hose for

evidence of a fuel leak. If a fuel leak is evident,
INSTALL a new fuel tank filler pipe or hose.

*

Fuel tank leaking.

*

CHECK the fuel tank for evidence of a fuel leak. If

a fuel leak is evident, INSTALL a new fuel tank.

*

Fuel tank ventilation

pipe or hose leaking.

*

CHECK the fuel tank ventilation pipe and hose for

evidence of a fuel leak. If a fuel leak is evident,
INSTALL a new fuel tank ventilation pipe or hose.

*

PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES - VEHICLES WITH
1.8L DURATORQ-TDCI (KENT) DIESEL ENGINE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM

WARNINGS:

Do not smoke or carry lighted tobacco of any type when working on or near any fuel

related components. Highly flammable mixtures are always present and may ignite.
Failure to follow these instructions may result in personal injury.

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

always observe fuel handling precautions. Failure to follow this instruction may result in
personal injury.

CAUTIONS:

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 install blanking plugs to any open orifices or lines.

Always carry out the cleaning process before carrying out any repairs to the fuel

system components to prevent foreign material ingress to the components.

REFER to:

Quick Release Coupling

(310-00 Fuel

System - General Information, General Procedures).

1

Using a suitable piece of clear plastic pipe,
manufacture and install a pipe between the fuel filter

fuel supply line and fuel filter.

2

Start the engine, wait a few minutes and then
observe the clear plastic fuel pipe between the fuel

filter fuel supply line and fuel filter for signs of air
ingress.

3

Are any signs of air present in the clear plastic pipe?
Yes

GO to A2

.

No

For additional diagnostics,
REFER to:

Fuel Charging and Controls

(303-04D Fuel

Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).

A2: CHECK WHERE AIR IS ENTERING THE SYSTEM

Using suitable clean engine oil, apply the oil to each
of the fuel supply line and fuel return line

connections, unions and joints in turn and observe
the clear plastic pipe for visible signs of air after each
oil application.

1

Did the amount of air in the clear plastic fuel pipe
decrease when any of the connectors, unions or joints
were oiled?
Yes

INSTALL a new fuel pipe(s) as necessary. Test the
system for normal operation.

No

GO to A3

.

A3: CHECK THE FUEL LEVEL SENSOR FOR AIR INGRESS

Drain the fuel tank.
REFER to:

Fuel Tank Draining

(310-00 Fuel System -

General Information, General Procedures).

1

Fill the fuel tank with 10 liters of diesel.

2

REFER to:

Quick Release Coupling

(310-00 Fuel

System - General Information, General Procedures).

3

Using a suitable piece of clear plastic pipe,
manufacture and install a pipe between the fuel filter

to fuel pump fuel supply line.

4

NOTE: Make sure that the engine is at normal
operating temperature.

Start the engine, wait a few minutes and observe
the clear plastic pipe for signs of air ingress.

5

Are any signs of air present in the clear plastic pipe?
Yes

INSTALL a new fuel level sensor or fuel tank to fuel
filter supply pipe as necessary.

No

INSTALL a new fuel filter.
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).

PINPOINT TEST B : AIR INGRESS INTO THE FUEL LINES - VEHICLES WITH
2.0L DURATORQ-TDCI (DW) DIESEL ENGINE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

B1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM

WARNINGS:

Do not smoke or carry lighted tobacco of any type when working on or near any fuel

related components. Highly flammable mixtures are always present and may ignite.
Failure to follow these instructions may result in personal injury.

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

always observe fuel handling precautions. Failure to follow this instruction may result in
personal injury.

CAUTIONS:

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 install blanking plugs to any open orifices or lines.

Always carry out the cleaning process before carrying out any repairs to the fuel

injection system components to prevent foreign matter ingress to the components.

The generator must be protected from contamination. Failure to follow this

instruction may result in failure of the generator.

Start the engine, wait a few minutes and then
observe the clear plastic fuel pipe in the fuel pump

fuel return line for signs of air ingress.

1

Are any signs of air present in the clear plastic fuel pipe?
Yes

GO to B2

.

No

For additional diagnostics for Fuel Charging and
Controls,
REFER to:

Fuel Charging and Controls

(303-04E 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, Diagnosis and Testing).

B2: CHECK WHERE AIR IS ENTERING THE SYSTEM

Using suitable clean engine oil, apply the oil to each
of the fuel supply line and fuel return line

connections, unions and joints in turn and observe
the clear plastic pipe for visible signs of air after each
oil application.

1

Did the amount of air in the clear plastic pipe decrease
when any of the connectors, unions or joints were oiled?
Yes

INSTALL a new fuel pipe(s) as necessary. Test the
system for normal operation.

No