Ford Galaxy

Continental injectors with a faulty internal coating (vehicles built Feb–Sep 2019). The coating delaminates and blocks the injector. Ford service action: free injector replacement (Ford TSB-20-2335). Affected vehicles: Transit, Ranger, Focus, Mondeo, S-Max, Galaxy, Edge.

Symptoms: Hesitation, poor idle, power reduction, increased fuel consumption, limp mode

Faulty injectors generate excessive soot that prematurely clogs the DPF. On the high-output variant (190 hp), soot also blocks the low-pressure filter of the dual EGR system. Repair requires simultaneous replacement of injectors AND DPF (TSB-20-2335). Replacing the DPF alone does not resolve the issue long-term.

Symptoms: Fault codes P2002, P02EC, P02FA, check engine light, power reduction

The high-pressure pump on the 2.0 TDCi 132 kW typically fails from 150,000 km. Failed pumps can shed metal particles into the fuel system and damage injectors.

Symptoms: Poor or no start, severe power loss, fault codes P0087 (rail pressure too low).

The 2.0 EcoBlue uses a wet-belt drive to the oil pump. Coating wear generates fine particles that clog the oil pump strainer. Low oil pressure damages bearings, crankshaft, camshaft and turbocharger.

Symptoms: No early warning symptoms; when clogged: oil pressure warning, metallic knocking, turbocharger wear, in the worst case sudden engine failure

The intake port geometry of the 2.0 EcoBlue routes a disproportionate amount of EGR soot particles into the middle cylinders. Piston rings grind soot into the cylinder walls; from around 135,000 km compression loss is possible.

Symptoms: High fuel trim correction data, power loss, oil consumption, injector quantity fault codes, workshop finding: cylinder wall scoring in cylinders 2 and 3

The NOx sensor in the SCR exhaust aftertreatment system fails prematurely. Fault code P20EE is typical. AdBlue consumption increases measurably as the system reverts to a base map. Sensor replacement is relatively inexpensive.

Symptoms: Check engine light P20EE, increased AdBlue consumption, occasional no-start after many km

The variable turbine geometry actuator on the 2.0 TDCi 132 kW fails electrically, often due to connector corrosion or actuator motor wear. In many cases only the electronics are faulty.

Symptoms: Sudden power loss, engine in limp mode, boost pressure regulation fault codes.

Ford recalled hundreds of thousands of Galaxy and S-Max vehicles: the original rear axle trailing arm bolts can fracture due to corrosion. If they break, the vehicle loses rear axle control — acute accident risk.

Ford recalled Galaxy models with EcoBoost engines and manual gearboxes because heavy clutch wear could cause overheating and fracture of the clutch pressure plate — with a risk of fire in the engine bay.

In the Galaxy III too, the wiring harness runs beneath the washer fluid reservoir. Overfilling or a leaking reservoir allows washer fluid to attack the cable insulation, causing cooling fan failures, AC problems and P0003 fault codes.