Ford Galaxy / Ford S-MAX. Manual — part 597

GO to B3

.

B3: 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

Protect the generator with lint-free material to
prevent contamination.

3

Disconnect the fuel filter fuel supply line quick
release coupling.

REFER to:

Spring Lock Couplings

(310-00 Fuel

System - General Information, General Procedures).

4

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

and the fuel tank to fuel filter supply line.

5

Remove the lint-free material.

6

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

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

7

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

(310-01C 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).

PINPOINT TEST C : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE -
VEHICLES WITH 1.8L DURATORQ-TDCI (KENT) DIESEL ENGINE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

C1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE

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 material ingress to the components.

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

instruction may result in failure of the generator.

Disconnect the fuel filter fuel supply line quick
release coupling.

REFER to:

Quick Release Coupling

(310-00 Fuel

System - General Information, General
Procedures).

1

NOTE: Make sure that the hand pressure pump
arrow indicating the direction of fuel flow is
pointing towards the fuel filter.

Install the special tool between the fuel filter fuel
supply line quick release coupling and the fuel

filter union.

2

Operate the hand pressure pump at least 30
times.

3

REFER to:

Quick Release Coupling

(310-00 Fuel

System - General Information, General

Procedures).

4

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

pump fuel return line and fuel return line union.

5

Observe the flow of fuel in the clear plastic pipe.

6

Does the fuel from the fuel tank flow freely with no
restrictions?
Yes

GO to Pinpoint Test

A.

No

REPAIR or INSTALL a new fuel filter fuel supply
line.

PINPOINT TEST D : FUEL FILTER FUEL SUPPLY LINE BLOCKAGE -
VEHICLES WITH 2.0L DURATORQ-TDCI (DW) DIESEL ENGINE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

D1: CHECK THE FUEL FILTER FUEL SUPPLY LINE FOR BLOCKAGE

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.

Protect the generator with lint-free material to
prevent contamination.

1

Disconnect the fuel filter fuel supply line quick
release coupling.

REFER to:

Quick Release Coupling

(310-00 Fuel

System - General Information, General
Procedures).

2

Install the special tool between the fuel filter fuel
supply line quick release coupling and the fuel

filter union.

3

Operate the hand pressure pump.

4

Observe the flow of fuel in the clear plastic fuel
pipe in the fuel pump fuel return line.

5

Does the fuel from the fuel tank flow freely with no
restrictions?
Yes

GO to Pinpoint Test

B.

No

REPAIR or INSTALL a new fuel filter fuel supply
line.