Ford Galaxy / Ford S-MAX. Manual — part 595

Fuel System - General Information - Fuel
System—1.8L Duratorq-TDCi (Lynx)
Diesel/2.0L Duratorq-TDCi (DW) Diesel

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

Print

Diagnosis and Testing

Special Tool(s)

General Equipment

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step.

4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom

Chart.

Symptom Chart

Hand Pressure Pump with Adapter Kit

310-110

Worldwide Diagnostic System (WDS)

Mechanical

Electrical

Fuel level

Fuel leak(s)

Fuel line(s)

Fuel filler cap

Fuel filter

Fuel tank

Fuel tank ventilation hose

Fuel tank filler hose

Wiring harness

Electrical connector(s)

Fuel level sensor

Symptom

Possible Sources

Action

Engine cranks
but does not
start

Fuel charging and

controls.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

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

*

Air ingress into the

fuel lines.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

engine. GO to Pinpoint Test

A.

Vehicles with 2.0L

Duratorq-TDCi (DW) diesel engine. GO to Pinpoint

*

Test

B.

Contaminated fuel.

*

DRAIN and REFILL the fuel system with fresh fuel.

INSTALL a new fuel filter.
REFER to:

Fuel Filter

(310-01B Fuel Tank and Lines

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

Fuel Filter

(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).

*

Poor starting

Fuel charging and

controls.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

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

*

Air ingress into the

fuel lines.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

engine. GO to Pinpoint Test

A.

Vehicles with 2.0L

Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test

B.

*

Contaminated fuel.

*

DRAIN and REFILL the fuel system with fresh fuel.

INSTALL a new fuel filter.
REFER to:

Fuel Filter

(310-01B Fuel Tank and Lines

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

Fuel Filter

(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).

*

Engine starts but
immediately
stops

Fuel charging and

controls.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

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

*

Air ingress into the

fuel lines.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

engine. GO to Pinpoint Test

A.

Vehicles with 2.0L

Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test

B.

*

Poor idling

Fuel charging and

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

*

controls.

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

Air ingress into the

fuel lines.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

engine. GO to Pinpoint Test

A.

Vehicles with 2.0L

Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test

B.

*

Contaminated fuel.

*

DRAIN and REFILL the fuel system with fresh fuel.

INSTALL a new fuel filter.
REFER to:

Fuel Filter

(310-01B Fuel Tank and Lines

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

Fuel Filter

(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).

*

Engine lacks
power

Fuel tank to fuel

filter fuel supply line
blocked.

*

CHECK the fuel supply lines for damage. INSTALL

a new fuel filter fuel supply line.

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

engine. GO to Pinpoint Test

C.

Vehicles with 2.0L

Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test

D.

*

*

Fuel filter blocked.

*

INSTALL a new fuel filter.

REFER to:

Fuel Filter

(310-01B Fuel Tank and Lines

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

Fuel Filter

(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).

*

Fuel charging and

controls.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

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

*

Air ingress into the

fuel lines.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

engine. GO to Pinpoint Test

A.

Vehicles with 2.0L

*

Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test

B.

Contaminated fuel.

*

DRAIN and REFILL the fuel system with fresh fuel.

INSTALL a new fuel filter.
REFER to:

Fuel Filter

(310-01B Fuel Tank and Lines

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

Fuel Filter

(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).

*

Engine misfire

Fuel charging and

controls.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

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

*

Air ingress into the

fuel lines.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

engine. GO to Pinpoint Test

A.

Vehicles with 2.0L

Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test

B.

*

Excessive fuel
consumption

Fuel charging and

controls.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

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

*

Air ingress into the

fuel lines.

*

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel

engine. GO to Pinpoint Test

A.

Vehicles with 2.0L

Duratorq-TDCi (DW) diesel engine. GO to Pinpoint
Test

B.

*

Contaminated fuel.

*

DRAIN and REFILL the fuel system with fresh fuel.

INSTALL a new fuel filter.
REFER to:

Fuel Filter

(310-01B Fuel Tank and Lines

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

Fuel Filter

(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).

*