Ford Galaxy 1994 - 1997 engines 2.0 & 2.3

Problem: Failed emmissions test. Failed secondary air injection pump.

Solution: The problem may be caused by a faulty check/control valve. To rectify this problem, a revised and updated injection pump hose for the secondary injection pump should be fitted. The PCM may also need to be programmed to a new calibration setting.

Ford Galaxy 2000

Problem: Poor response from speed control.

Solution: A common problem is a damaged speed control vacuum pump. These tend to suffer from water ingress. To remidy the problem, a new vacuum pump should be fitted along with an extended ventilation hose.

Ford Galaxy upto 2003 with booster heating / parking heater

Problem: Ticking noises from the passenger area when the booster heater is used.

Solution: A common problem is vibrations from the metering pump being transmitted through the fuel line to the body of the vehicle. A revised and updated fuel line with modified clips should be fitted between the metering pump and the booster heater.

Ford Galaxy

Problem: Various electrical gremlins.

Solution: A common problem has been identified as the electrical connectors in the battery junction box working loose. The connectors should be tightened to the correct torque.

Ford Galaxy 1.9 TDi automatic AG5 2001 - 2002

Problem: Gurgling noise from the intake system.

Solution: The noise is most likely caused by excessive boost pressure and air swirl in the turbocharger intake tract. This is caused by the software of the PCM (Powertrain (engine) Control Module). The PCM with software level 1516 should be replaced with a revised PCM with software version 1561. This will reduce boost pressure during overrun. The revised PCM has been installed since 03/2002.

Ford Galaxy 2000 - 2002 2.0 2.3 DOHC

Problem: Poor driveability between 2000 and 5000 rpm.

Solution: These Galaxys have an incorrect octane number matching. The solution is to re-calibrate the PCM with a different VID (Vehicle Identification Data) block. The revised VID block has been used in production since 06/2002.

Ford Galaxy upto 2000

Problem: Power steering belt slips in wet conditions.

Solution: The probable cause is water spray passing through the towing eye opening or gap between the undershield and side member. This spray may cause the accessory belt to slip. First, the belt should be checked for tension and wear. Secondly, the engine undershield should be checked for correct seating and adjusted as necessary. Thirdly, the towing eye cover should be checked for gaps and replaced if missing to prevent further ingress of spray.

Ford Galaxy 1.9 TDi (81kW) 1999 - 2000

Problem: Engine will stall but restart or loss of power.

Solution: The problem could be a faulty powertrain control module (PCM). If fault codes 425DA3 and 425A23 are triggered, a new PCM should be fitted using the latest software version. A PCM with revised software has been fitted since 04/2000.

Ford Galaxy 1.9 TDi 6-speed manual 2000

Problem: Rattling noises fron the gearbox area.

Solution: The most probable cause is vibration between the gearshift cables and their outer sleeves. The solution is to fit revised gearshift and selector cables. Revised cables have been fitted since 06/2000.

Ford Galaxy 1.9 TDi with booster heater or auxillary heater

Problem: Dense black smoke coming from the exhaust pipe of the booster heater.

Solution: Brief smoke during start up and light emission of white smoke in cold temperatures are normal. However, thick continuous black smoke indicates a problem. The cause could be the booster heater metering pump is damaged or there are excessive deposits in the burner which is over saturated with unburned fuel. The solution is to fit a revised booster heater metering pump and, if necessary, a new booster heater unit. A revised booster heater has been fitted since 09/1999.

Ford Galaxy 1.9 TDi upto 1999

Problem: Complete loss of power.

Solution: This problem may be caused by moisture ingress into the MAF (Mass Air Flow) sensor. This can cause a reduced supply of intake air and therefore a loss of power. The solution is to fit a revised intake air duct and a new MAF sensor. A revised intake air duct has been used in production since 08/1999.

Ford Galaxy 2000

Problem: Lack of power from, or failure of, the A/C system, with or without leaks at the evaporator.

Solution: Severe air pollution combined with a high level of sulphur dioxide and moisture ingress through the pollen filter may cause this, leading to corrosion on the evaporator. Install a new evaporator and a modified pollen filter (activated carbon) to rectify the problem; after having checked that a revised pollen filter frame and additional foam filter have been installed.

Ford Galaxy 1998

Problem: Power loss, especially in first and second gears.

Solution: Probably caused by a vibrating engine cover damaging the PCV hose leading to the air intake tube. Install a new damping element under the engine cover to rectify the problem.

Ford Galaxy 1998 - 1999

Problem: Damaged A/C compressor, compressor clutch does not turn on after engine on with A/C switch on, A/C failure.

Solution: If the compressor fails, the air conditioning system needs to be drained, the compressor removed and the refrigerant oil checked. A new compressor, a new compressor clutch, a new collector/dehydrator, a new modified compressor suction pipe and high pressure pipe with oil resevoir, a new expansion valve and a new auxiliary drive belt should be installed if there is no dark discolouration of the refrigerant oil. If there is discolouration, install all new lines and all new component assemblies throughout.

The powertrain control module should be recalibrated with the aid of diagnostic scanner as well. The compressor clutch must also be engaged at idle speed when it is engaged for the first time after the new compressor installation.

Ford Galaxy 1997

Problem: Foul odours from the air circulation system in the form of:

1. Smell of exhaust gases- exhaust gases are drawn into the passenger compartment from the engine compartment through the interior air filter because of incorrect installation of the bulkhead cover and/or damaged seal at the bulkhead.

2. Petrol smell on deceleration- the fuel vapour lines at the activated carbon canister are not completely pushed onto the connector.

3. Musty smell from the air conditioning system is a result of the run off valve on the driver or passenger side being blocked or damaged.

4. An unpleasant smell when the blower is switched on which is caused by a blocked run off hose in the engine compartment, allowing condensed water to drip onto the heater housing. Stagnant fluid residues can't escape after switching on the air conditioning.

5. A smell of cement when the air conditioning is switched on, which is a result of the welds on the air conditioning system not being cleaned properly during production.


1. Check the seal and bulkhead cover, and remove if necessary. Rework the retaining tabs of the bulkhead cover.

2. Reconnect the fuel vapour lines at the activated charcoal canister.

3. Remove the passenger or driver side run off valve and rework it.

4. For vehicles with rubber valves on the run off hose: remove and throw away the rubber valve. Clean the rubber hose of any obstructions. Leave the air conditioning switched on for one hour and then check the run off hose again. If the hose is blocked again then renew the heater.

5. Renew the air conditioning front evaporator (and the rear one if it is there).

Ford Galaxy  1995 - 1997

Problem: Engine running irregularly.

Solution: Irregular engine running may be a result of a damaged fuel pressure wire loom caused by sharp edges on the boost pressure line. It can be rectified by installing an additional wiring sleeve Ø 13mm, L=140mm around the wiring loom to the fuel pressure resevoir. Repair damaged wiring looms as necessary.

Ford Galaxy 1995 - 1997

Problem: Timing belt wear.

Solution: The belt may be rubbing against the edge of the timing belt tensioner and the vibration damper thrust washer. To rectify, remove the fuel injection pump and install a revised fuel injection pump bracket, a new timing belt and a revised timing belt tensioner.

Ford Galaxy

Problem: Knocking noise from the front whilst cornering.

Solution: Install a new power assisted steering low pressure pipe assembly which damps out the vibration caused by pressure fluctuations in the PAS system.