Ford Galaxy and S-Max diesel engine ECU failure - cutting out after start
Ford Galaxy (Mk II) and Ford S-Max (Facelift) diesel models are fitted with this commonly failing ECU. Malfunction of this engine ECU begins intermittently causing the vehicle to cut out almost as soon as the engine has started. Further attempts at running the vehicle will result in the engine starting, immediately cutting out and being unable to restart.
The engine management light (EML) will be illuminated and the message ‘Engine Malfunction’ will appear on the Galaxy and S-Max instrument cluster. When the vehicle is scanned with diagnostic equipment fault codes will often be found for sensor reference faults, low supply voltage and ECM/PCM power relay de-energised performance.
As the fault progresses multiple sensors are disturbed and essentially shut down by the engine ECU. Common sensors to be affected include the rail pressure sensor, ambient air temperature sensor, exhaust gas temperature and exhaust gas differential pressure sensor (P0194, P0072, P2452, P042A).
As this internal ECU fault develops the starting problems for the Galaxy/S-Max will become more permanent and will result in no cranking or starting of the engine. At this point you may find that communications is not possible to the engine management system via diagnostic tools.
To resolve these symptoms replacing the faulty ECU with a new one from the manufacturer was the only option, this would also incur programming costs. However, the defect has not yet been resolved by the manufacturer, meaning that even new ECUs are predisposed to fail, usually outside the short one-year warranty.
We can now offer a better solution. Our in-house R&D team have identified manufacturing defects within these Delphi DCM3.5 engine ECUs affecting not only Ford S-Max and Galaxy diesel engines but also: C-Max, Mondeo, Kuga and Focus models.
We can now offer a full remanufacture service, resolving all internal ECU defects whilst retaining all programming information and providing an unlimited mile Lifetime Warranty. All this within 2-3 working days for a fraction of the cost of a new ECU.
Common Failure symptoms:
(Symptoms may be intermittent or permanent)
- Cutting out
- Not running / none start
- Engine management light (EML) illuminated
- ‘Engine Malfunction’ message on dash
- Will not crank
- No communication to ECU
Common fault codes:
- P06A6 – Sensor Reference Voltage A Malfunction
- P06A7 – Sensor Reference Voltage B Malfunction
- P06A8 – Sensor Reference Voltage C Malfunction
- P0194 – Fuel Pressure Sensor Intermittent
- P068A – ECM/PCM Power Relay De-Energised – Too Early
- U0100 – Lost Communication With PCM
- U0401 – Invalid Data From PCM
- P0606 – PCM Processor
- P060C – PCM Processor Performance
- P0194 – Rail Pressure Sensor Malfunction
- P0072 – Ambient Air Pressure Sensor Signal Too Low
- P2452 – Exhaust Gas Differential Pressure Sensor Malfunction
- P042A – Exhaust Gas Temperature Sensor 2 Malfunction
Affected Vehicles:
- Galaxy (Mk III) 2010-2015
- S-Max (Facelift) 2010-2015
- C-Max (Mk II) 2010-2015
- Focus (Mk III) 2011-2015
- Mondeo (Mk IV) 2007-2015
- Kuga (Mk II) 2010-2015
Click here for more information on Mondeo and Kuga or Focus and C-Max
(Can’t find your part number? Check our full engine ECU catalogue for S-Max or Galaxy)
Test and rebuild:
We test each engine ECU on our bespoke Hardware In-the-Loop testing stations which will highlight every fault within the unit. Once all internal faults have been identified our technicians will rebuild the S-Max/Galaxy engine ECU and replace all common failing components with versions that are higher rated than standard, and then extensively re-test to ensure that no faults remain.
Programming:
All programming information is retained, meaning that the ECU will be simply plug and play once you receive it back from us.
Quality:
Our strict quality control: encompassing testing, components and workmanship will ensure only the highest level of work is carried out to meet our lifetime warranty standards. Due to our extremely high standards we work very closely with dealerships and specialists, offering a better solution to replacement. Our work defect rate is lower than 0.49% on all our rebuilds, so you can be assured of our very high standard of work.
Warranty:
Lifetime unlimited mileage*
How do I get my unit rebuilt?
To pay for the rebuild select your part number above and then click: Get yours rebuilt
Print the payment/booking confirmation email.
Package the S-Max/Galaxy ECU inside a sturdy box with plenty of packaging material (make sure you include your confirmation email in the box).
Send us your package by tracked courier (the shipping instructions are on the confirmation email).
Once received we will test, rebuild and return your engine ECU with an unlimited mileage lifetime warranty. (if your unit turns out not to be faulty then we will refund your payment less a small testing fee and return shipping)
What if I don’t want to pay up front?
This is not a problem, if you prefer this option then follow the following steps:
Fill in and submit this test form.
Print the booking confirmation email.
Package the engine ECU inside a sturdy box with plenty of packaging material (make sure you include your confirmation email in the box).
Send us your package by tracked courier (the shipping instructions are on the confirmation email).
Once received, we will test your engine management ECU and call you to advise on the outcome of testing, if your unit is faulty and you choose to go ahead with the rebuild then we will take payment over the phone using a debit/credit card.
We will then rebuild your engine ECU and return it to you with an unlimited mileage warranty.
If you require further information regarding this Ford S-Max/Galaxy engine ECU then please contact us.