Ford Galaxy / Ford S-MAX. Manual — part 384

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).

Fuel injector(s).

*

REFER to the WDS.

*

EGR valve incorrect

operation.

*

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

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).

*

Coolant in the

combustion chamber.

*

CARRY OUT a cooling system pressure test.

REFER to: Engine Cooling (303-03D Engine
Cooling - 2.0L Duratorq-TDCi (DW) Diesel,
Diagnosis and Testing).
REMOVE the cylinder head. INSPECT the
cylinder head, cylinder head gasket and
cylinder bores for wear or damage.

*

Engine misfire and
glow plug indicator
is flashing

DTC detected.

*

REFER to the WDS.

*

Engine misfire

Low fuel tank level.

*

CHECK the fuel tank level is greater than four

liters. If the fuel tank level is less than four
liters, 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 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
injection supply manifold, 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

(Kent) Diesel/2.0L Duratorq-TDCi (DW) Diesel
(310-00, Diagnosis and Testing).

*

EGR valve incorrect

operation.

*

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

Diagnosis and Testing).

*

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).

*

Engine overheats.

*

REFER to: Engine Cooling (303-03D Engine

Cooling - 2.0L Duratorq-TDCi (DW) Diesel,
Diagnosis and Testing).

*

ECT sensor.

*

REFER to the WDS.

*

CKP sensor.

*

REFER to the WDS.

*

CMP sensor.

*

REFER to the WDS.

*

MAF sensor.

*

REFER to the WDS.

*

MAP sensor.

*

REFER to the WDS.

*

Fuel injector(s).

*

REFER to the WDS.

*

FRP sensor.

*

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.

*

*

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.

*

Damaged cylinder

*

REMOVE the cylinder head. INSPECT the

*

head gasket.

cylinder head gasket and cylinder bores for
wear or damage.

Engine knock at
idle and glow plug
indicator is flashing

DTC detected.

*

REFER to the WDS.

*

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 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).

*

*

*

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

(303-01F 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).

*

Excessive carbon

build up.

*

REMOVE the cylinder head. INSPECT the

cylinder head and pistons for signs carbon
build up.

*

Worn or damaged oil

pump.

Major mechanical

engine failure.

*

*

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.

*

Fuel injector(s).

*

REFER to the WDS.

*

Engine knock
during acceleration
and glow plug
indicator is flashing

DTC detected.

*

REFER to the WDS.

*

Engine knock
during acceleration

Fuel injector(s).

*

REFER to the WDS.

*

Major mechanical

engine failure.

*

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).

*

Fuel pump fuel

pressure regulator.

*

REFER to the WDS.

*

Fuel pump.

*

REFER to the WDS.

*

Excessive fuel
consumption and
glow plug indicator
is flashing

DTC detected.

*

REFER to the WDS.

*

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 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).

*

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 WDS.

*

EGR valve incorrect

operation.

*

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

Diagnosis and Testing).

*

Turbocharger vacuum

diaphragm unit.

*

REFER to: Turbocharger (303-04G Fuel

Charging and Controls - Turbocharger - 2.0L
Duratorq-TDCi (DW) Diesel, Diagnosis and
Testing).

*

Air ingress into the

fuel lines.

*

REFER to: Fuel System - 1.8L Duratorq-TDCi

(Kent) Diesel/2.0L Duratorq-TDCi (DW) Diesel
(310-00, 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

*