Ford Galaxy / Ford S-MAX. Manual — part 373

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

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).

*

Low cylinder

compression.

*

REFER to:

Engine

(303-01C Engine - 2.3L

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

*

Catalytic converter

blocked.

*

REMOVE and visually INSPECT the catalytic

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

*

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).

*

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 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).

*

*
*

Vehicle speed sensor

(VSS).

*

REFER to the Ford approved diagnostic tool.

*

CHT 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.

*

APP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

REFER to the Ford approved diagnostic tool.

*

Fuel temperature

sensor.

*

REFER to the Ford approved diagnostic tool.

*

FRP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pressure

regulator.

*

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

throttle vacuum
control solenoid.

*

CHECK the intake manifold EGR throttle vacuum

control solenoid vacuum lines for kinks or
restrictions.

REFER to the Ford approved diagnostic tool.

*

*

Black smoke at
idle and glow plug
indicator is
flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Black smoke at
idle

Air cleaner element

blocked.

*

INSTALL a new air cleaner element as

necessary.

*

Glow plug system.

*

REFER to the Ford approved diagnostic tool.

*

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).

*

Catalytic converter

blocked.

*

REMOVE and visually INSPECT the catalytic

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

*

CHT 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.

*

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

throttle vacuum
control solenoid.

*

CHECK the intake manifold EGR throttle vacuum

control solenoid vacuum lines for kinks or
restrictions.

REFER to the Ford approved diagnostic tool.

*

*

Excessive black
smoke during
acceleration and
glow plug indicator
is flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

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.

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).

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).

*

Catalytic converter

blocked.

*

REMOVE and visually INSPECT the catalytic

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

*

APP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CKP 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.

*

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

throttle vacuum
control solenoid.

*

CHECK the intake manifold EGR throttle vacuum

control solenoid vacuum lines for kinks or
restrictions.

REFER to the Ford approved diagnostic tool.

*

*

Black smoke at
cruising speeds
and glow plug
indicator is
flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Black smoke at
cruising speeds

Air cleaner element

blocked.

*

INSTALL a new air cleaner element.

*

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).

*

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).

*

Catalytic converter

blocked.

*

REMOVE and visually INSPECT the catalytic

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

*

CHT 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.

*

Intake manifold EGR

*

CHECK the intake manifold EGR throttle

*

throttle.

butterfly for obstructions and correct operation.

REFER to the Ford approved diagnostic tool.

*

Intake manifold EGR

throttle vacuum
control solenoid.

*

CHECK the intake manifold EGR throttle vacuum

control solenoid vacuum lines for kinks or
restrictions.

REFER to the Ford approved diagnostic tool.

*

*

Blue smoke and
glow plug indicator
is flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Blue smoke

Engine burning oil.

*

CARRY OUT a controlled oil consumption test

over 1000 km (600 miles). CONFIRM that the oil
consumption is less than 0.1 of a litre per 1000
km (600 miles).
REFER to:

Engine

(303-01C Engine - 2.3L

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

*

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).

*

*
*

Worn or damaged

valve guide(s), piston
ring(s), cylinder bore
(s), cylinder head or
gasket.

*

REMOVE the cylinder head. INSPECT the

cylinder head, pistons and cylinder bores 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).

*

Positive crankcase

ventilation (PCV)
system.

*

INSPECT for visible signs of damage or

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

*

Turbocharger oil

return tube blocked
or damaged.

*

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).

*

White smoke and
glow plug indicator
is flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

White smoke

Water in fuel.

*

CHECK for signs of water in the diesel.

*