Ford Galaxy / Ford S-MAX. Manual — part 220

Engine - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-
TDCi (92kW/125PS) - Lynx - Engine

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

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Description and Operation

Engine

Transversely-mounted 4-cylinder in-line turbo diesel engine with direct fuel injection,
based on the 1.8L Duratorq DI
1.8L cubic capacity with 74kw (100 PS) and 92kW (125 PS)
Turbocharger with variable turbine geometry and intercooler
Common rail fuel injection system
Dual mass flywheel for the reduction of drive noise

Common rail fuel injection system

High-pressure pump for the generation of pressure in the fuel rail with integral transfer
pump for fuel supply
Fuel rail for constant fuel pressure
Piezo fuel injectors for optimal metering of the fuel quantity
Variable pilot and main injection for optimization of noise emissions

Engine management

A Siemens Powertrain Control Module (PCM) (one box design) with 128 pins for fuel-
quantity regulation, control of the fuel injectors, exhaust gas recirculation and integrated

immobilizer
Camshaft Position (CMP) sensor for determining the injection sequence
Knock Sensor (KS) for reduction of combustion noise
Electrical actuator for turbocharger guide vane adjustment for optimisation of boost
pressure control

Engine emission control

Fulfils European emissions standard level IV
Oxidation catalytic converter
Actuator motor-controlled Exhaust Gas Recirculation (EGR) valve with integral position
sensor
EGR cooler for the reduction of nitrogen oxides (NOx)
Vacuum-controlled intake manifold flap with position sensor for optimization of exhaust
gas recirculation rate

Engine power output torque 74kw (100 PS)

Engine power output torque 92kw (125 PS)

Engine - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-
TDCi (92kW/125PS) - Lynx - Engine

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

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Diagnosis and Testing

Special Tool(s)

General Equipment

Materials

Specification

WSK-M2G349-A7

1. 1. Verify the customer concern by operating the system

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

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.

Visual Inspection Chart

Symptom Chart

Compression Test Adapter

303-1049A

Worldwide Diagnostic System (WDS)

Name

Adhesive - Loctite 243

Mechanical

Electrical

Coolant leaks
Oil leaks
Fuel system leaks
Visibly damaged or worn parts
Loose or missing nuts or bolts

Fuse(s)
Loose or corroded connector(s)
Control module
Damaged or worn switch(es)

Symptom

Possible Sources

Action

Loss of oil

Oil leaks on components

that are either coated in oil
themselves or on
components local to them.

*

CHECK for evidence of oil leaks on

components. Use an ultraviolet (UV) leak
tester if an oil leak is not evident.
INSTALL new gaskets or components as
required.

*

Internal or external leak at

the oil cooler.

*

CHECK the coolant expansion tank for a

film of oil on the coolant surface.
INSTALL a new oil cooler or oil cooler
gasket.

*

Leak at the crankshaft seal.

*

INSTALL a new crankshaft seal.

*

Leaks from oil carrying

components or basic engine.

*

CHECK for cracks in oil-carrying

components of the basic engine by
means of a UV leak test. INSTALL new
components or seals as necessary.

*

Oil consumption

Use of the wrong type of

engine oil.

*

DETERMINE the last type of engine oil

used and compare with the specification.
Change the engine oil to the

*