Ford Galaxy / Ford S-MAX. Manual — part 358

(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4/2.5L Duratec
(162kW/220PS) - VI5, Removal and
Installation).

EGR valve

sticking open.

*

REFER to: (303-08A Engine Emission Control

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

Engine Emission Control

(Diagnosis and

Testing),

Engine Emission Control

(Diagnosis and

Testing).

*

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.

*

CKP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Knock sensor

(KS).

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

FRP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Engine stumbling

Engine ignition.

*

Carry out an ignition system diagnosis using

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.

*

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).

*

FRP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

EGR valve

sticking open.

*

REFER to: (303-08A Engine Emission Control

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

Engine Emission Control

(Diagnosis and

Testing),

Engine Emission Control

(Diagnosis and

Testing).

*

Engine lacks power

Engine ignition.

*

Carry out an ignition system diagnosis using

the Ford approved diagnostic tool.

*

Brakes binding.

*

CHECK the braking system.

REFER to:

Anti-Lock Control

(206-09A Anti-

Lock Control, Diagnosis and Testing).

*

Vehicle

overloaded, or
excessive wind
resistance (roof
racks, towing

*

ADVISE the customer about the effects of

overloading the vehicle and wind resistance
on the fuel consumption.

*

etc).

Air cleaner

element
blocked.

*

INSTALL a new air cleaner element as

necessary.

*

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).

*

Kinked or

restricted fuel
lines.

*

INSPECT the fuel lines. INSTALL new

components as necessary. TEST the system
for normal operation.

*

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).

*

*

*

*

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).

*

EGR valve

sticking open.

*

REFER to: (303-08A Engine Emission Control

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

Engine Emission Control

(Diagnosis and

Testing),

Engine Emission Control

(Diagnosis and

*

Testing).

Vehicle speed

sensor (VSS).

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

ECT 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.

*

FRP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Incorrect valve

timing.

*

CHECK the valve timing.

*

Low cylinder

compression.

*

CHECK the cylinder compression.

*

Catalytic

converter
blocked.

*

REMOVE and visually INSPECT the catalytic

converter for damage. INSTALL a new
catalytic converter as necessary. REFER to:
(309-00A Exhaust System - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4)

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

(Removal

and Installation),

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

(Removal and

Installation).

*

Black smoke at idle

Air cleaner

element
blocked.

*

INSTALL a new air cleaner element as

necessary.

*

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.

*

ECT sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

FRP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Catalytic

converter
blocked.

*

REMOVE and visually INSPECT the catalytic

converter for damage. INSTALL a new
catalytic converter as necessary. REFER to:
(309-00A Exhaust System - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4)

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

(Removal

and Installation),

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

(Removal and

Installation).

*

Incorrect valve

timing.

*

CHECK the valve timing.

*

Excessive black smoke
during acceleration

Air cleaner

element
blocked.

*

INSTALL a new air cleaner element as

necessary.

*

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).

*

*

*

*

EGR valve

sticking open.

*

REFER to: (303-08A Engine Emission Control

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

Engine Emission Control

(Diagnosis and

Testing),

Engine Emission Control

(Diagnosis and

Testing).

*

CKP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

KS.

*

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.

*

FRP sensor.

*

Carry out a full engine diagnosis using the

guided diagnostic menu in the Ford approved
diagnostic tool.

*

Catalytic

converter
blocked.

*

REMOVE and visually INSPECT the catalytic

converter for damage. INSTALL a new
catalytic converter as necessary.

*

Black smoke at cruising
speeds

Air cleaner

element

*

INSTALL a new air cleaner element.

*