Ford Galaxy / Ford S-MAX. Manual — part 374

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

(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).
INSTALL a new fuel pump, fuel injectors, fuel
rail, and high-pressure fuel supply lines. REFER
to: (303-04D Fuel Charging and Controls - 1.8L
Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx)

Fuel Pump

(Removal and Installation),

Fuel Injectors

(Removal and Installation),

Fuel Rail

(Removal and Installation).

*

Fuel injector(s).

*

REFER to the Ford approved diagnostic tool.

*

EGR valve incorrect

operation.

*

REFER to:

Engine Emission Control

(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, Diagnosis and Testing).

*

Incorrect valve

timing.

*

CHECK the valve timing.

REFER to:

Timing Belt

(303-01E Engine - 1.8L

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

*

Coolant in the

combustion chamber.

*

CARRY OUT a cooling system pressure test.

REFER to:

Engine Cooling

(303-03D Engine

Cooling - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx,
Diagnosis and Testing).
REMOVE the cylinder head. INSPECT the cylinder
head, cylinder head gasket and cylinder bores
for wear or damage.
REFER to:

Cylinder Head

(303-01E Engine - 1.8L

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

*

Engine misfire and
glow plug indicator
is flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Engine misfire

Low fuel tank level.

*

CHECK the fuel tank level is greater than four

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

*

Incorrect or

contaminated fuel.

*

CHECK for signs of contamination such as

strange odors from the fuel tank.

CHECK for signs of water or petrol 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

(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).
INSTALL a new fuel pump, fuel injectors, fuel
rail, and high-pressure fuel supply lines. REFER
to: (303-04D Fuel Charging and Controls - 1.8L
Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx)

Fuel Pump

(Removal and Installation),

Fuel Injectors

(Removal and Installation),

Fuel Rail

(Removal and Installation).

Air ingress into the

fuel lines.

*

REFER to:

Fuel System - 2.0L Duratec-HE

(MI4)/2.3L Duratec-HE (MI4)/2.5L Duratec (VI5)

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

*

EGR valve incorrect

operation.

*

REFER to:

Engine Emission Control

(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, Diagnosis and Testing).

*

Low cylinder

compression.

*

REFER to:

Engine

(303-01C Engine - 2.3L

Duratec-HE (118kW/160PS) - MI4, Diagnosis
and Testing).

*

Worn or damaged

valve(s), tappet(s) or
camshaft(s).

*

REMOVE the cylinder head. INSPECT the

cylinder head, valves, tappets and camshafts for
signs of wear or damage.
REFER to:

Cylinder Head

(303-01E Engine - 1.8L

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

*

Damaged cylinder

head gasket.

*

REMOVE the cylinder head. INSPECT the

cylinder head gasket and cylinder bores for wear
or damage.
REFER to:

Cylinder Head

(303-01E Engine - 1.8L

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

*

Engine overheats.

*

REFER to:

Engine Cooling

(303-03D Engine

Cooling - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx,
Diagnosis and Testing).

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CMP sensor.

*

REFER to the Ford approved diagnostic tool.

*

MAF sensor.

*

REFER to the Ford approved diagnostic tool.

*

MAP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

REFER to the Ford approved diagnostic tool.

*

FRP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pump.

*

REFER to the Ford approved diagnostic tool.

*

Intake manifold EGR

throttle.

*

CHECK the intake manifold EGR throttle

butterfly for obstructions and correct operation.

REFER to the Ford approved diagnostic tool.

*

*

Intake manifold EGR

*

CHECK the intake manifold EGR throttle vacuum

*

throttle vacuum
control solenoid.

control solenoid vacuum lines for kinks or
restrictions.

REFER to the Ford approved diagnostic tool.

*

Engine knock at
idle and glow plug
indicator is
flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Engine knock at
idle

Low engine oil level.

*

CHECK the engine oil level. REFILL 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 petrol 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

(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).
INSTALL a new fuel pump, fuel injectors, fuel
rail, and high-pressure fuel supply lines. REFER
to: (303-04D Fuel Charging and Controls - 1.8L
Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx)

Fuel Pump

(Removal and Installation),

Fuel Injectors

(Removal and Installation),

Fuel Rail

(Removal and Installation).

*

*
*

Dual mass flywheel.

*

INSPECT the dual mass flywheel for damage.

INSTALL a new dual mass flywheel as necessary.

*

Incorrect valve

timing.

*

CHECK the valve timing.

REFER to:

Timing Belt

(303-01E Engine - 1.8L

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

*

Excessive carbon

build up.

*

REMOVE the cylinder head. INSPECT the

cylinder head and pistons for signs carbon build
up.
REFER to:

Cylinder Head

(303-01E Engine - 1.8L

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

*

Worn or damaged oil

pump.

Major mechanical

engine failure.

*

*

REFER to:

Engine

(303-01C Engine - 2.3L

Duratec-HE (118kW/160PS) - MI4, Diagnosis
and Testing).

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

REFER to the Ford approved diagnostic tool.

*

Engine knock
during acceleration
and glow plug
indicator is
flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Engine knock
during acceleration

Fuel injector(s).

*

REFER to the Ford approved diagnostic tool.

*

Major mechanical

engine failure.

*

REFER to:

Engine

(303-01C Engine - 2.3L

Duratec-HE (118kW/160PS) - MI4, Diagnosis
and Testing).

*

Fuel pressure

regulator.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pump.

*

REFER to the Ford approved diagnostic tool.

*

Excessive fuel
consumption and
glow plug indicator
is flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Excessive fuel
consumption

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.

*

Fuel filter blocked.

*

INSTALL a new fuel filter element.

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 system leak(s).

*

CHECK the system for fuel leak(s). REPAIR or

INSTALL new parts as necessary.

*

Dual mass flywheel.

*

INSPECT the dual mass flywheel for damage.

INSTALL a new dual mass flywheel as necessary.

*

Incorrect engine oil.

*

INSTALL a new oil filter and engine oil.

*

Generator.

*

REFER to the Ford approved diagnostic tool.

*

EGR valve incorrect

operation.

*

REFER to:

Engine Emission Control

(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, Diagnosis and Testing).

*

Air ingress into the

fuel lines.

*

REFER to:

Fuel System - 2.0L Duratec-HE

(MI4)/2.3L Duratec-HE (MI4)/2.5L Duratec (VI5)

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

*

Incorrect valve

timing.

*

CHECK the valve timing.

REFER to:

Timing Belt

(303-01E Engine - 1.8L

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

*

Turbocharger.

*

REFER to:

Turbocharger

(303-04I Fuel Charging

and Controls - Turbocharger - 1.8L Duratorq-
TDCi (74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).

*

Slipping clutch.

*

REFER to:

Manual Transaxle and Clutch

(308-00

Manual Transmission/Transaxle and Clutch -
General Information, Diagnosis and Testing).

*

Low cylinder

compression.

*

REFER to:

Engine

(303-01C Engine - 2.3L

Duratec-HE (118kW/160PS) - MI4, Diagnosis
and Testing).

*