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Fuel Pump > < Fuel Rail

S-MAX.Galaxy 2006.5 (03.2006-)

Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel - Fuel Injectors S-MAX/Galaxy 2006.5 (03/2006-)
Removal and Installation

Special Tool(s)
303-174
Gauge, Bolt Angle

310-110A
Hand Pressure Pump with Adapter Kit

Removal

WARNING:
WARNING:Refer to: Diesel Fuel System Health and Safety Precautions (100-00, Description and Operation).
NOTE:
NOTE:Removal steps in this procedure may contain installation details.
  1. Remove the intake manifold.
    Refer to: Intake Manifold (303-01D, Removal and Installation).
  1. Clean the fuel injectors, fuel rail, high-pressure fuel supply lines and surrounding areas.
    Refer to: Fuel Injection Component Cleaning (303-04D, General Procedures).

  1.  
    1. CAUTION:
      CAUTION:Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned.
      CAUTION:
      CAUTION:Make sure that all openings are sealed. Use new blanking caps.
      Discard the high-pressure fuel supply lines.

Installation
  1. NOTE:
    NOTE:Make sure that new components are installed.

  1. CAUTION:
    CAUTION:Make sure that the clips are correctly located.

  1. NOTE:
    NOTE:Make sure that new components are installed.
    NOTE:
    NOTE:Only tighten the nuts finger tight at this stage.

  1. Special Tool(s): 303-174
    Torque:
    Stage 1:
    4 Nm
    Stage 2:
    45°

  1. Torque: 23 Nm

  1. CAUTION:
    CAUTION:Use lint free cloth.
    Protect the generator to prevent contamination.

  1. Refer to: Quick Release Coupling (310-00, General Procedures).

  1. Special Tool(s): 310-110A
  1. Operate the hand pressure pump at least 30 times.
  1. CAUTION:
    CAUTION:The starter motor operation must not exceed 10 seconds at a time. After 10 seconds turn the ignition switch to position 0 and allow the starter motor to cool for 30 seconds before operating the starter motor again.
    Start the engine and allow to idle until it reaches normal operating temperature
  1. Stop the engine.

  1. Special Tool(s): 310-110A

  1. Refer to: Quick Release Coupling (310-00, General Procedures).
  1. Remove the lint-free material.

  1. Torque: 9 Nm
  1. Install the intake manifold.
    Refer to: Intake Manifold (303-01D, Removal and Installation).

Fuel Pump > < Fuel Rail