Ford Galaxy / Ford S-MAX. Manual — part 372

Installation).

Fuel lines damaged

or blocked.

*

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).

*

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).

*

Glow plugs.

*

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).

*

Low cylinder

compression.

*

REFER to:

Engine

(303-01C Engine - 2.3L

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

*

Crankshaft position

(CKP) sensor.

*

REFER to the Ford approved diagnostic tool.

*

Camshaft position

(CMP) sensor.

*

REFER to the Ford approved diagnostic tool.

*

Cylinder head

temperature (CHT)
sensor.

*

REFER to the Ford approved diagnostic tool.

*

PCM.

*

REFER to the Ford approved diagnostic tool.

*

Fuel rail fuel

pressure sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pump fuel

pressure regulator.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pump.

*

REFER to the Ford approved diagnostic tool.

*

Fuel injector(s).

*

REFER to the Ford approved diagnostic tool.

*

Poor starting and
glow plug indicator
is flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Poor starting

Low fuel tank fuel

level.

*

CHECK the fuel tank fuel level is greater than

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

*

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).

*

Air cleaner element

blocked.

*

INSTALL a new air cleaner element.

*

Glow plugs.

*

REFER to the Ford approved diagnostic tool.

*

Fuel system leak.

*

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

system as necessary.

*

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).

*

Fuel system

restriction.

*

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 engine oil.

*

INSTALL a new engine oil filter and engine oil.

*

Catalytic converter

blocked.

*

REMOVE and visually INSPECT the catalytic

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

*

Low cylinder

compression.

*

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.

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel temperature

sensor.

*

REFER to the Ford approved diagnostic tool.

*

Mass air flow (MAF)

sensor.

*

REFER to the Ford approved diagnostic tool.

*

Manifold absolute

pressure (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 pressure

regulator.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pump.

*

REFER to the Ford approved diagnostic tool.

*

Intake manifold

Exhaust gas
recirculation (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.

*

*

Engine starts but
immediately stops
and glow plug
indicator is
flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Engine starts but
immediately stops

Air cleaner element

blocked.

*

INSTALL a new air cleaner element.

*

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).

*

PCM relay.

*

CARRY OUT the relay component test. REFER to

Wiring Diagrams.

*

Dual mass flywheel.

*

INSPECT the dual mass flywheel for damage.

INSTALL a new dual mass flywheel as necessary.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CMP sensor.

*

REFER to the Ford approved diagnostic tool.

*

CHT sensor.

*

REFER to the Ford approved diagnostic tool.

*

PCM.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pressure

regulator.

*

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.

*

Poor idling and
glow plug indicator
is flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Poor idling

Low fuel tank fuel

level.

*

CHECK the fuel tank fuel level is greater than

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

*

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).

*

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).

*

Dual mass flywheel.

*

INSPECT the dual mass flywheel for damage.

INSTALL a new dual mass flywheel as necessary.

*

Fuel injector(s).

*

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.

*

CKP sensor.

*

REFER to the Ford approved diagnostic tool.

*

FRP sensor.

*

REFER to the Ford approved diagnostic tool.

*

Fuel pressure

*

REFER to the Ford approved diagnostic tool.

*

regulator.

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.

*

*

Engine stumbling
and glow plug
indicator is
flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Engine stumbling

Low fuel level.

*

CHECK the fuel tank level is greater than four

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

*

Dual mass flywheel.

*

INSPECT the dual mass flywheel for damage.

INSTALL a new dual mass flywheel as necessary.

*

Accelerator pedal

position (APP)
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.

*

Engine lacks power
and glow plug
indicator is
flashing

DTC detected.

*

REFER to the Ford approved diagnostic tool.

*

Engine lacks power

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 as

necessary.

*

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).

*

Kinked or restricted

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).

*

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).

*

Turbocharger.
Turbocharger

vacuum diaphragm
unit.

*
*

INSPECT the vacuum line(s) for visible signs of

damage or blockage. CLEAN, REPAIR or INSTALL
new parts as necessary.
REFER to:

Turbocharger

(303-04I Fuel Charging

and Controls - Turbocharger - 1.8L Duratorq-

*