Ford Galaxy / Ford S-MAX. Manual — part 382

Diagnosis and Testing).

Fuel system

restriction.

*

REFER to:

Fuel System - 1.8L Duratorq-TDCi

(Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel

(310-00 Fuel System - General Information,
Diagnosis and Testing).

*

Incorrect engine oil.

*

INSTALL a new engine oil filter and engine oil.

*

Catalytic converter

blocked.

*

REMOVE and visually INSPECT the catalytic

converter for damage. INSTALL a new catalytic
converter as necessary.
REFER to:

Catalytic Converter

(309-00E

Exhaust System - 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).

*

Low cylinder

compression.

*

REFER to:

Engine

(303-01F Engine - 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).

*

CKP sensor.

*

REFER to the WDS.

*

ECT sensor.

*

REFER to the WDS.

*

Fuel temperature

sensor.

*

REFER to the WDS.

*

Mass air flow (MAF)

sensor.

*

REFER to the WDS.

*

Manifold absolute

pressure (MAP)
sensor.

*

REFER to the WDS.

*

Fuel injector(s).

*

REFER to the WDS.

*

FRP sensor.

*

REFER to the WDS.

*

Fuel pump fuel

pressure regulator.

*

REFER to the WDS.

*

Fuel pump.

*

REFER to the WDS.

*

Intake air shut-off

throttle.

*

CHECK the intake air sut-off throttle for

obstructions and correct operation.

REFER to the WDS.

*

*

Intake air shut-off

throttle vacuum
control solenoid.

*

CHECK the intake air shut-off throttle vacuum

control solenoid vacuum lines for kinks or
restrictions.

REFER to the WDS.

*

*

Engine starts but
immediately stops
and glow plug
indicator is flashing

DTC detected.

*

REFER to the WDS.

*

Engine starts but
immediately stops

Air cleaner element

blocked.

*

INSTALL a new air cleaner element.

*

Air ingress into the

fuel lines.

*

REFER to:

Fuel System - 1.8L Duratorq-TDCi

(Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel

(310-00 Fuel System - General Information,
Diagnosis and Testing).

*

PCM relay.

*

CARRY OUT a relay component test.

*

Dual mass flywheel.

*

INSPECT the dual mass flywheel for damage.

INSTALL a new dual mass flywheel as
necessary.

*

CKP sensor.

*

REFER to the WDS.

*

CMP sensor.

*

REFER to the WDS.

*

ECT sensor.

*

REFER to the WDS.

*

PCM.

*

REFER to the WDS.

*

Fuel pump fuel

pressure regulator.

*

REFER to the WDS.

*

Intake air shut-off

throttle.

*

CHECK the intake air shut-off throttle for

obstructions and correct operation.

REFER to the WDS.

*

*

Intake air shut-off

throttle vacuum
control solenoid.

*

CHECK the intake air shut-off throttle vacuum

control solenoid vacuum lines for kinks or
restrictions.

REFER to the WDS.

*

*

Poor idling and
glow plug indicator
is flashing

DTC detected.

*

REFER to the WDS.

*

Poor idling

Low fuel tank fuel

level.

*

CHECK the fuel tank fuel level is greater than

four liters. If the fuel tank fuel level is less then
four liters, FILL with fuel.

*

Air cleaner element

blocked.

*

INSTALL a new air cleaner element.

*

Fuel filter blocked.

*

INSTALL a new fuel filter element.

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).

*

Incorrect or

contaminated fuel.

*

CHECK for signs of contamination such as

strange odors from the fuel tank.

CHECK for signs of water or gasoline in the

diesel.

If contaminated fuel is found, DRAIN the

complete fuel system. FLUSH the fuel system
through with clean diesel.
REFER to:

Fuel Tank Draining

(310-00 Fuel

System - General Information, General
Procedures).
INSTALL a new fuel filter element.
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).
INSTALL a new fuel pump, fuel injectors, fuel
rail, and high-pressure fuel supply lines.
REFER to:

Fuel Pump

(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, Removal and Installation) /

Fuel Injectors

(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, Removal
and Installation) /
Fuel Rail (303-04D Fuel Charging and Controls
- 2.0L Duratorq-TDCi (DW) Diesel, Removal

*

*

*

and Installation).

Air ingress into the

fuel lines.

*

REFER to:

Fuel System - 1.8L Duratorq-TDCi

(Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel

(310-00 Fuel System - General Information,
Diagnosis and Testing).

*

EGR valve incorrect

operation.

*

REFER to: Engine Emission Control (303-08D,

Diagnosis and Testing).

*

Dual mass flywheel.

*

INSPECT the dual mass flywheel for damage.

INSTALL a new dual mass flywheel as
necessary.

*

Fuel injector(s).

*

REFER to the WDS.

*

MAF sensor.

*

REFER to the WDS.

*

MAP sensor.

*

REFER to the WDS.

*

CKP sensor.

*

REFER to the WDS.

*

FRP sensor.

*

REFER to the WDS.

*

Fuel pump fuel

pressure regulator.

*

REFER to the WDS.

*

Fuel pump.

*

REFER to the WDS.

*

Intake air shut-off

throttle.

*

CHECK the intake air shut-off throttle butterfly

for obstructions and correct operation.

REFER to the WDS.

*

*

Intake air shut-off

throttle vacuum
control solenoid.

*

CHECK the intake air shut-off throttle vacuum

control solenoid vacuum lines for kinks or
restrictions.

REFER to the WDS.

*

*

Engine stumbling
and glow plug
indicator is flashing

DTC detected.

*

REFER to the WDS.

*

Engine stumbling

Low fuel level.

*

CHECK the fuel tank level is greater than four

litres. If the fuel tank level is less than four
litres, FILL with fuel.

*

Dual mass flywheel.

*

INSPECT the dual mass flywheel for damage.

INSTALL a new dual mass flywheel as
necessary.

*

Accelerator pedal

position (APP) sensor.

*

REFER to the WDS.

*

Fuel injector(s).

*

REFER to the WDS.

*

FRP sensor.

*

REFER to the WDS.

*

Fuel pump.

*

REFER to the WDS.

*

Engine lacks power
and glow plug
indicator is flashing

DTC detected.

*

REFER to the WDS.

*

Engine lacks power

Brakes binding.

*

CHECK the braking system.

REFER to: Brake System (206-00 Brake
System - General Information, Diagnosis and
Testing).

*

Vehicle overloaded,

or excessive wind
resistance (roof racks,
towing etc).

*

ADVISE the customer about the effects of

overloading the vehicle and wind resistance on
the fuel consumption.

*

Air cleaner element

blocked.

*

INSTALL a new air cleaner element as

necessary.

*

Fuel filter blocked.

*

INSTALL a new fuel filter element.

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).

Kinked or restricted

fuel lines.

*

REFER to: Spring Lock Couplings (310-00,

General Procedures).

*

Air ingress into the

fuel lines.

*

REFER to: Spring Lock Couplings (310-00,

General Procedures).

*

Turbocharger.
Turbocharger vacuum

diaphragm unit.

*
*

INSPECT the vacuum line(s) for visible signs of

damage or blockage. CLEAN, REPAIR or
INSTALL new parts as necessary.
REFER to: Turbocharger (303-04G Fuel
Charging and Controls - Turbocharger - 2.0L
Duratorq-TDCi (DW) Diesel, Diagnosis and
Testing).

*

Incorrect valve

timing.

*

CHECK the valve timing.

REFER to:

Timing Belt

(303-01F Engine - 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).

*

Low cylinder

compression.

*

REFER to:

Engine

(303-01F Engine - 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).

*

Catalytic converter

blocked.

*

REMOVE and visually INSPECT the catalytic

converter for damage. INSTALL a new catalytic
converter as necessary.
REFER to:

Catalytic Converter

(309-00E

Exhaust System - 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).

*

EGR valve incorrect

operation.

*

REFER to: Engine Emission Control (303-08D,

Diagnosis and Testing).

*

Charge air cooler

blocked or cracked.

Charge air cooler

pipes split or cracked.

Charge air cooler pipe

retaining clips missing
or loose.

*

*

*

INSPECT for visible signs of damage or

blockage. CLEAN, REPAIR or INSTALL new
parts as necessary.

*

Incorrect or

contaminated fuel.

*

CHECK for signs of contamination such as

strange odors from the fuel tank.

CHECK for signs of water or gasoline in the

diesel.

If contaminated fuel is found, DRAIN the

complete fuel system. FLUSH the fuel system
through with clean diesel.
REFER to:

Fuel Tank Draining

(310-00 Fuel

System - General Information, General
Procedures).
INSTALL a new fuel filter element.
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

*

*

*