Ford Galaxy / Ford S-MAX. Manual — part 605

Description

Fuel tank filler pipe

Fuel tank filler pipe cap

Fill limit vent valve

Evaporative emission canister

Evaporative emission canister dust filter

Fuel tank support straps

Fuel tank vent valve(s)

Fuel pump and sender unit (including fuel filter)

Fuel supply line

Evaporative emission canister to evaporative emission canister purge
valve line

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 two fuel tank vent valves venting through a fuel limit
vent valve and into an evaporative emission canister which absorbs the fuel vapor. The fuel
tank vent valve will prevent fuel loss from the fuel tank if the vehicle becomes inverted.

Fuel lines

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Description

Fuel line cover

Fuel supply line

Evaporative emission canister to evaporative emission canister purge
valve 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 pump and sender unit

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Description

Fuel tank locking ring

Fuel pump and sender unit

Fuel filter

Fuel pump and sender unit seal

Fuel tank level sensor float and arm

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

The fuel pump and sender unit consists of a fuel sender, a fuel filter and a high pressure
fuel pump with pressure regulator. The fuel tank module filter has been designed as a non-
serviceable item and will last the lifetime of the vehicle. If the fuel tank module fuel filter
becomes blocked a new fuel pump and sender unit must be installed.
For additional information, refer to:

Fuel Pump and Sender Unit

(310-01A Fuel Tank and

Lines - 2.0L EcoBoost SCTi (149kW/203PS) - MI4/2.0L Duratec-HE (107kW/145PS) -
MI4/2.0L Duratec-HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE (118kW/160PS) -
MI4/2.5L Duratec (162kW/220PS) - VI5, Removal and Installation).
The fuel pump is a turbine type pump which is an integral part of the fuel pump and sender
unit. The fuel tank module fuel sender communicates directly with the instrument cluster
which drives the fuel gauge informing the driver the amount of fuel that is currently in the
fuel tank.

CAUTION: Take extra care not to damage the fuel tank level sensor float and arm.

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NOTE: Make sure that the installation marks are aligned.

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

Fuel Tank

(310-01A Fuel Tank and Lines - 2.0L

EcoBoost SCTi (149kW/203PS) - MI4/2.0L Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE (118kW/160PS) - MI4/2.5L Duratec
(162kW/220PS) - VI5, Removal and Installation).

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

Fuel tank vent valve

Description

Fuel tank vent valve

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

The fuel tank vent valve also acts as a fuel tank breather with a dust filter located at the
atmospheric port of the evaporative emission canister. 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 fuel filter is blocked.

Fill limit vent valve

Description

Fill limit vent valve

The fill limit vent valve is an intermediate ventilation valve between the fuel tank vent
valves and the evaporative emission canister.

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

Evaporative emission system

The evaporative emission system consists of an evaporative emission canister, evaporative
emission canister purge valve and vacuum lines.
For additional information, refer to:

Evaporative Emissions

(303-13 Evaporative Emissions,

Description and Operation).

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