Ford Galaxy / Ford S-MAX. Manual — part 365

Fuel Charging and Controls - 2.5L Duratec
(162kW/220PS) - VI5 - Fuel Charging and
Controls

S-MAX/Galaxy 2006.5 (02/2006-)

Print

Diagnosis and Testing

General Equipment

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step.

4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom

Chart.

Symptom Chart

Ford approved diagnostic tool

Mechanical

Electrical

Fuel leak(s)
Vacuum line(s)
Gasket(s)
Seal(s)
Fuel injector(s)
Throttle body
Fuel rail
Fuel supply line

Wiring harness
Electrical connector(s)
Throttle body
Fuel injector(s)
Powertrain control module (PCM)

Symptom

Possible Sources

Action

Engine does not crank

Passive anti-theft

system (PATS).

*

CHECK the PATS LED extinguishes

within 3 seconds when the ignition is
turned on.
REFER to:

Anti-Theft - Passive

(419-

01B Anti-Theft - Passive, Diagnosis
and Testing).

*

Starting system.

*

REFER to: Starting System (303-

06A, Diagnosis and Testing) /
Starting System (303-06B,
Description and Operation) / Starting
System (303-06C, Diagnosis and
Testing) / Starting System (303-06D,
Diagnosis and Testing) / Starting
System (303-06E, Diagnosis and
Testing).

*

Ignition switch.

*

REFER to the Wiring Diagrams.

*

Powertrain

control module
(PCM).

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

Engine cranks but does not start

Inertia fuel

shutoff (IFS)
switch.

*

RESET the IFS switch.

*

Low fuel system

*

Check the fuel system pressure.

*

pressure.

REFER to:

Fuel System Pressure

Check - 2.5L Duratec (162kW/220PS)
- VI5

(310-00 Fuel System - General

Information, General Procedures).

Fuel lines

damaged or
blocked.

*

INSPECT the fuel lines. INSTALL new

components as necessary. TEST the
system for normal operation.

*

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).

*

Fuel pump and

sender unit.

*

INSTALL a new fuel pump and

sender unit.
REFER to:

Fuel Pump and Sender Unit

(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).

*

Crankshaft

position (CKP)
sensor.

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

Camshaft position

(CMP) sensor.

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

PCM.

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

Fuel rail fuel

pressure (FRP)
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.

*

Incorrect valve

timing.

*

CHECK the valve timing.

*

Low cylinder

compression.

*

TEST the cylinder compression.

*

Poor starting

Low fuel system

pressure.

*

Check the fuel system pressure.

REFER to:

Fuel System Pressure

Check - 2.5L Duratec (162kW/220PS)
- VI5

(310-00 Fuel System - General

Information, General Procedures).

*

Fuel system leak.

*

CHECK the system for fuel leak(s).

REPAIR the system as necessary.

*

Fuel system

restriction.

*

INSPECT the fuel system. INSTALL

new components as necessary. TEST
the system for normal operation.

*

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).

*

Air cleaner

element blocked.

*

INSTALL a new air cleaner element.

*

Incorrect engine

oil.

*

INSTALL a new engine oil filter and

engine oil.

*

Incorrect power

steering fluid.

*

DRAIN and REFILL the power

steering system with the correct fluid.

REFER to:

Power Steering System

Bleeding

(211-00 Steering System -

General Information, General
Procedures) /

Power Steering System Flushing

(211-00 Steering System - General
Information, General Procedures) /

Power Steering System Filling

(211-

00 Steering System - General
Information, General Procedures).

*

CKP sensor.

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

Engine coolant

temperature
(ECT) sensor.

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

Fuel injector(s).

*

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 as necessary.

*

Low cylinder

compression.

*

TEST the engine cylinder

compression.

*

Engine starts but immediately
stops

Air cleaner

element blocked.

*

INSTALL a new air cleaner element.

*

CKP sensor.

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

CMP sensor.

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

PCM.

*

Carry out a full engine diagnosis

using the guided diagnostic menu in
the Ford approved diagnostic tool.

*

Low fuel system

pressure.

*

Check the fuel system pressure.

REFER to:

Fuel System Pressure

*

Check - 2.5L Duratec (162kW/220PS)
- VI5

(310-00 Fuel System - General

Information, General Procedures).

Fuel system

restriction.

*

INSPECT the fuel system. INSTALL

new components as necessary. TEST
the system for normal operation.

*

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).

*

Poor idling

Air cleaner

element blocked.

*

INSTALL a new air cleaner element.

*

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:

Fuel Rail

(303-04C Fuel

Charging and Controls - 2.5L Duratec
(162kW/220PS) - VI5, Removal and
Installation).

*

*

*

*

Low fuel system

pressure.

*

Check the fuel system pressure.

REFER to:

Fuel System Pressure

Check - 2.5L Duratec (162kW/220PS)
- VI5

(310-00 Fuel System - General

Information, General Procedures).

*

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).

*

Fuel injectors.

*

INSPECT the fuel injectors. CLEAN

*