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Ford Galaxy / Ford S-MAX. Manual - part 367

(162kW/220PS) - VI5, Removal and
Installation).

Positive

crankcase
ventilation (PCV)
system.

INSPECT for visible signs of damage

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

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 (303-01
Engine - 2.5L Duratec (VI5), Removal
and Installation).

White smoke

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).

Coolant in the

combustion
chamber.

CARRY OUT a cooling system

pressure test.
REFER to: Engine Cooling (303-03
Engine Cooling - 2.5L Duratec (VI5),
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 (303-01
Engine - 2.5L Duratec (VI5), Removal
and Installation).

Engine misfire

Engine ignition.

Carry out an ignition system

diagnosis using the Ford approved
diagnostic tool.

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

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).

Engine operating

temperature too
high.

REFER to: Engine Cooling (303-03

Engine Cooling - 2.5L Duratec (VI5),
Diagnosis and Testing).

ECT sensor.

Carry out a full engine diagnosis

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

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.

KS.

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.

FRP sensor.

Carry out a full engine diagnosis

using the guided diagnostic menu in
Ford approved diagnostic tool.

Low cylinder

compression.

CHECK the engine compression.

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 (303-01
Engine - 2.5L Duratec (VI5), Removal
and Installation).

Damaged

cylinder head

REMOVE the cylinder head. INSPECT

the cylinder head gasket and cylinder

gasket.

bores for wear or damage.
REFER to: Cylinder Head (303-01
Engine - 2.5L Duratec (VI5), Removal
and Installation).

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.

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

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).

KS.

Carry out a full engine diagnosis

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

CKP 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.

Incorrect valve

timing.

CHECK the valve timing.

Excessive carbon

build up.

REMOVE the cylinder head. INSPECT

the cylinder head and pistons for
signs carbon build up.
REFER to: Cylinder Head (303-01
Engine - 2.5L Duratec (VI5), Removal
and Installation).

Worn or damaged

oil pump.

Worn or damaged

timing chain or
sprocket.

Major mechanical

engine failure.

INSPECT the engine components.

Engine knock during acceleration

KS.

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.

Major mechanical

engine failure.

REFER to: Cylinder Head (303-01

Engine - 2.5L Duratec (VI5), Removal
and Installation).

NOTE: Before proceeding with
any of the actions in relation
to the possible sources for
excessive fuel consumption, a
fuel consumption test located
in the toolbox menu of the
Ford approved diagnostic tool
must be carried out.

Excessive fuel consumption

Brakes binding.

CHECK the braking system.

REFER to:

Anti-Lock Control

(206-

09A Anti-Lock Control, 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 system leak

(s).

CHECK the system for fuel leak(s).

REPAIR or INSTALL new parts as
necessary.

Fuel filter

blocked.

INSTALL a new fuel filter.

REFER to:

Fuel Filter

(310-01A Fuel

Incorrect engine

oil.

INSTALL a new oil filter and engine

oil.

Generator.

REFER to the Ford approved

diagnostic tool.

Slipping clutch.

REFER to: Clutch (308-01 Clutch -

Vehicles With: 6-Speed Manual
Transmission (M66), Diagnosis and
Testing).

ECT 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.

PCM calibration.

Using the Ford approved diagnostic

tool, CHECK for the availability of a
calibration update.

Incorrect valve

timing.

CHECK the valve timing.

Low cylinder

compression.

CHECK the engine compression.

Content .. 365 366 367 368 ..