Ford Galaxy / Ford S-MAX. Manual — part 357

Fuel Charging and Controls - 2.0L
Duratec-HE (107kW/145PS) - MI4/2.0L
Duratec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Duratec-HE (118kW/160PS) -
MI4 - Fuel Charging and Controls

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

Print

Diagnosis and Testing

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

Ford approved diagnostic tool

Mechanical

Electrical

Fuel leak(s)
Vacuum line(s)
Gasket(s)
Seal(s)
Fuel injector(s)
Throttle body
Fuel rail
Fuel supply line

Wiring harness
Electrical connector(s)
Throttle body
Fuel injector(s)
Powertrain control module (PCM)

Symptom

Possible Sources

Action

Engine does not crank

Passive anti-

theft system
(PATS).

*

CHECK the PATS LED extinguishes within 3

seconds when the ignition is turned on.
REFER to:

Anti-Theft - Passive

(419-01B Anti-

Theft - Passive, Diagnosis and Testing).

*

Starting

system.

*

REFER to:

Starter Motor

(303-06A Starting

System - 2.0L Duratec-HE (107kW/145PS) -
MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and
Installation) /

Starting System

(303-06C

Starting System - 2.5L Duratec
(162kW/220PS) - VI5, Diagnosis and
Testing) /

Starting System

(303-06E Starting

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,
Diagnosis and Testing).

*

Ignition switch.

*

REFER to the Wiring Diagrams.

*

Powertrain

control module

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved

*

(PCM).

diagnostic tool.

Engine cranks but does not
start

Inertia fuel

shutoff (IFS)
switch.

*

RESET the IFS switch.

*

Low fuel

system
pressure.

*

Check the fuel system pressure.

REFER to:

Fuel System Pressure Check - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L
Duratec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Duratec-HE (118kW/160PS) - MI4

(310-00 Fuel System - General Information,
General Procedures).

*

Fuel lines

damaged or
blocked.

*

INSPECT the fuel lines. INSTALL new

components as necessary. TEST the system
for normal operation.

*

Fuel filter

blocked.

*

INSTALL a new fuel filter.

REFER to:

Fuel Filter

(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).

*

Fuel pump and

sender unit.

*

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).

*

Crankshaft

position (CKP)
sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Camshaft

position (CMP)
sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

PCM.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Fuel rail

pressure (FRP)
sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Fuel injectors.

*

INSPECT the fuel injectors. CLEAN the fuel

injectors or INSTALL a new set of fuel
injectors as required only after the checks
have been carried out.

*

Incorrect valve

timing.

*

CHECK the valve timing.

*

Low cylinder

compression.

*

TEST the cylinder compression.

*

Poor starting

Low fuel

system
pressure.

*

Check the fuel system pressure.

REFER to:

Fuel System Pressure Check - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L
Duratec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Duratec-HE (118kW/160PS) - MI4

(310-00 Fuel System - General Information,
General Procedures).

*

Fuel system

*

CHECK the system for fuel leak(s). REPAIR

*

leak.

the system as necessary.

Fuel system

restriction.

*

INSPECT the fuel system. INSTALL new

components as necessary. TEST the system
for normal operation.

*

Fuel filter

blocked.

*

INSTALL a new fuel filter.

REFER to:

Fuel Filter

(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).

*

Air cleaner

element
blocked.

*

INSTALL a new air cleaner element.

*

Incorrect

engine oil.

*

INSTALL a new engine oil filter and engine oil.

*

Incorrect

power steering
fluid.

*

DRAIN and REFILL the power steering system

with the correct fluid. REFER to: (211-00
Steering System - General Information)

Power Steering System Bleeding

(General

Procedures),

Power Steering System Flushing

(General

Procedures),

Power Steering System Filling

(General

Procedures).

*

CKP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Engine coolant

temperature
(ECT) sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Fuel injector

(s).

*

INSPECT the fuel injectors. CLEAN the fuel

injectors or INSTALL a new set of fuel
injectors as required only after the checks
have been carried out.

*

FRP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Low cylinder

compression.

*

TEST the engine cylinder compression.

*

Engine starts but
immediately stops

Air cleaner

element
blocked.

*

INSTALL a new air cleaner element.

*

CKP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

CMP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

PCM.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Low fuel

system
pressure.

*

Check the fuel system pressure.

REFER to:

Fuel System Pressure Check - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L
Duratec-HE Flex Fuel (107kW/145PS) -

*

MI4/2.3L Duratec-HE (118kW/160PS) - MI4

(310-00 Fuel System - General Information,
General Procedures).

Fuel system

restriction.

*

INSPECT the fuel system. INSTALL new

components as necessary. TEST the system
for normal operation.

*

Fuel filter

blocked.

*

INSTALL a new fuel filter.

REFER to:

Fuel Filter

(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).

*

Poor idling

Air cleaner

element
blocked.

*

INSTALL a new air cleaner element.

*

Incorrect or

contaminated
fuel.

*

CHECK for signs of contamination such as

strange odors from the fuel tank.

If contaminated fuel is found, DRAIN the

complete fuel system. FLUSH the fuel system
through with clean gasoline. INSTALL a new
fuel filter.
REFER to:

Fuel Filter

(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).

INSPECT the fuel injectors. CLEAN the fuel

injectors or INSTALL a new set of fuel
injectors as required only after the checks
have been carried out.

INSTALL a new fuel rail. REFER to: (303-04A

Fuel Charging and Controls - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE Flex
Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4)

Fuel Rail - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4

(Removal

and Installation),

Fuel Rail - 2.3L Duratec-HE
(118kW/160PS) - MI4

(Removal and

Installation).

*

*

*

*

Low fuel

system
pressure.

*

Check the fuel system pressure.

REFER to:

Fuel System Pressure Check - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L
Duratec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Duratec-HE (118kW/160PS) - MI4

(310-00 Fuel System - General Information,
General Procedures).

*

Fuel filter

blocked.

*

INSTALL a new fuel filter.

REFER to:

Fuel Filter

(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

*