Ford Galaxy / Ford S-MAX. Manual — part 288

REFER to:

Specifications

(303-01G Engine

- 2.2L Duratorq-TDCi (129kW/175PS) -
DW, Specifications).

Faulty positive crankcase

ventilation (PCV) system.

Hoses or ventilation or

breather valves are blocked.
This causes excessive
pressure in the crankcase
which causes more oil to
enter the combustion
chamber.

PCV oil separator is faulty

and engine oil can enter the
combustion chamber
through the intake
manifold.

*

-

-

CHECK if the PCV system is operating

correctly and repair as necessary. REFER
to:

Engine Emission Control

(303-08E

Engine Emission Control - 2.2L Duratorq-
TDCi (129kW/175PS) - DW, Diagnosis and
Testing).

*

Turbocharger seals.

*

INSTALL a new turbocharger. REFER to:

Turbocharger

(303-04K Fuel Charging and

Controls - Turbocharger - 2.2L Duratorq-
TDCi (129kW/175PS) - DW, Removal and
Installation).

*

Damaged gaskets or

mating surfaces.

Cylinder head gasket is

damaged or mating face are
warped.

Valve stem seals are worn

and engine oil can enter the
combustion chamber
between the valve stem and
the valve stem guide.

*

-

-

CHECK the gaskets and mating surfaces

for damage.

Remove the cylinder head. REFER to:

Cylinder Head

(303-01G Engine - 2.2L

Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).CHECK the
mating faces, cylinder head gasket and
the evenness of the cylinder head and
engine block mating faces.

INSTALL new valve seals. REFER to:

Valve Stem Seals

(303-01G Engine - 2.2L

Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).

*

-

-

Piston ring or cylinder liner

wear.

*

INSTALL new components as necessary.

*

Damaged cylinder liners or

excessive clearance of
engine components.

Pistons.
Piston rings (clearance in

groove and end gap).

Cylinder liners.

*

-
-

-

CHECK the running surfaces and

clearances of the individual engine
components. INSTALL new components as
necessary. INSTALL a new cylinder block
if necessary.

Check the pistons and piston rings.

*

*

Coolant
consumption

Cooling system

components.

*

Check the cooling system components.

REFER to:

Engine Cooling

(303-03F

Engine Cooling - 2.2L Duratorq-TDCi
(129kW/175PS) - DW, Diagnosis and
Testing).

*

Oil cooler.

*

INSTALL a new oil cooler.

*

Damaged gaskets or

warped mating faces.

*

CHECK the cylinder head gasket for

damage. CHECK the cylinder head for
distortion.

*

Cracks or fractures in

engine components
surrounded by coolant, such
as cylinder liners and
cylinder head combustion
chamber.

*

DETERMINE the damaged engine

component(s) and install new component
(s) as necessary.

*

Engine will not

Battery or cables.

*

CHECK the battery, bracket and cables.

*

crank

Starter motor or cables.

*

CHECK the starting system. REFER to:

Starting System

(303-06E Starting

System - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission
Requirements: Stage IV, Diagnosis and
Testing).

*

Engine cranks but
will not start

Fuel tank is empty.

*

CHECK the fuel level.

*

Water in fuel.

*

Drain the water from the fuel system.

*

Fuel filter blocked.

*

INSTALL a new fuel filter. REFER to:

Fuel

Filter

(310-01D Fuel Tank and Lines - 2.2L

Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).

*

Engine intake air system.

*

CHECK the intake air system.

*

Glow plug faulty.

*

CHECK the glow plugs. INSTALL new glow

plugs as necessary. REFER to:

Glow Plug

(303-07E Glow Plug System - 2.2L
Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).

*

Engine management

system.

*

CHECK the engine management system.

*

Incorrect valve timing.

*

CHECK and adjust the valve timing.

REFER to:

Timing Belt

(303-01G Engine -

2.2L Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).

*

Broken or damaged timing

belt/timing chain or
pulley/sprocket.

*

CHECK the timing belt/timing chain and

sprockets/pulleys. INSTALL new
components as necessary. REFER to:

Timing Belt

(303-01G Engine - 2.2L

Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).

*

Very poor power
output or fuel
consumption too
high or engine
running rough.

Fuel charging system.

*

CHECK the fuel charging system. REFER

to:

Fuel Charging and Controls

(303-04F

Fuel Charging and Controls - 2.2L
Duratorq-TDCi (129kW/175PS) - DW,
Diagnosis and Testing).

*

Engine intake air system.

*

CHECK the intake air system. REFER to:

Intake Air Distribution and Filtering

(303-

12F Intake Air Distribution and Filtering -
2.2L Duratorq-TDCi (129kW/175PS) - DW,
Diagnosis and Testing).

*

Exhaust system blocked.

*

CHECK the exhaust system. REFER to:

Exhaust System

(309-00F Exhaust

System - 2.2L Duratorq-TDCi
(129kW/175PS) - DW, Description and
Operation).

*

Engine management

system.

*

CHECK the engine management system.

*

Turbocharger.

*

CHECK the turbocharger. REFER to:

Turbocharger

(303-04K Fuel Charging and

Controls - Turbocharger - 2.2L Duratorq-
TDCi (129kW/175PS) - DW, Diagnosis and
Testing).

*

Incorrect valve timing.

Timing belt/timing sprocket
or pulley/sprocket
damaged.

*

CHECK and adjust valve timing. INSTALL

new components as necessary. REFER to:

Timing Belt

(303-01G Engine - 2.2L

Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).

*

Engine - Oil Leaks

NOTE: Before installing new gaskets or oil seals, make sure that the fault is clearly
established.

If the oil leak cannot be identified clearly by a visual inspection, carry out an ultraviolet
(UV) test:

Ultraviolet (UV) Testing

1. 1. Clean the engine and transmission with a suitable cleaning fluid.

2. 2. Pour the UV-test fluid in accordance with the quantity specified by the

manufacturer through the oil filler neck into the engine and install the oil filler cap.

3. 3. Start the engine and let it run for about five minutes.

4. 4. Switch off the engine.

NOTE: If no leak can be found, road test the vehicle under various loads and check the
engine for leaks again.

Noisy running

Engine auxiliary

components loose or
damaged.

*

CHECK engine auxiliary components for

damage or looseness. CHECK and adjust
valve timing. INSTALL new components as
necessary. REFER to:

Timing Belt

(303-

01G Engine - 2.2L Duratorq-TDCi
(129kW/175PS) - DW, Removal and
Installation).

*

Noisy running,
misfiring or
knocking

Water in fuel or fuel

contaminated.

*

CHECK the fuel system for water or other

contamination.

*

Valve timing incorrect,

timing belt/chain or
pulley/sprocket damaged.

*

CHECK and adjust valve timing. INSTALL

new components as necessary. REFER to:

Timing Belt

(303-01G Engine - 2.2L

Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).

*

Noisy running or
valve train noise

Valve clearance too large

due to faulty valve tappets
or worn valve train
components.

*

INSTALL new hydraulic lash adjusters.

REFER to:

Camshafts

(303-01G Engine -

2.2L Duratorq-TDCi (129kW/175PS) - DW,
Removal and Installation).

*

Timing belt or timing chain

damaged.

*

INSTALL a new timing belt or timing

chain. REFER to:

Timing Belt

(303-01G

Engine - 2.2L Duratorq-TDCi
(129kW/175PS) - DW, Removal and
Installation).

*

Timing belt or timing chain

incorrectly tensioned.

*

CHECK the timing belt tension. INSTALL a

new timing belt or timing chain as
necessary. REFER to:

Timing Belt

(303-

01G Engine - 2.2L Duratorq-TDCi
(129kW/175PS) - DW, Removal and
Installation).

*

Noisy running or
engine noise

Engine components
Pistons.
Piston rings.
Connecting rod big end,

main bearing or thrust
bearing journals.

Connecting rods bent or

damaged.

*
-
-
-

-

CHECK the engine components for wear

or damage. Make sure all components are
within specification. INSTALL new
components as necessary. REFER to:

Specifications

(303-01G Engine - 2.2L

Duratorq-TDCi (129kW/175PS) - DW,
Specifications).

*

5. 5. Check the engine for oil leaks using a suitable UV lamp.

6. 6. Rectify any leaks found and check the engine for oil leaks.

Measure the compression pressure

WARNING: Do not carry out any repairs to the fuel injection system without checking

that the fuel pressure has dropped to zero and that the fuel temperature has either
reached ambient temperature or is below 30°C, whichever is the greater. Failure to follow
these instructions may result in personal injury.
NOTE: The powertrain control module (PCM) receives an error message when the fuel
pump relay is removed or electrical components are disconnected. This error message
must be deleted from the fault memory using the Ford diagnostic equipment after
completing the compression test.
NOTE: Valve clearance must be set correctly before performing a compression test. Make
sure the engine is at the normal operating temperature.
NOTE: The varying design of compression checking devices and fluctuating starter motor
speeds normally only allows for a comparison to be made of the compression pressures in
all cylinders.

1. 1. Using datalogger in the

Ford diagnostic equipment

, check that the fuel pressure

has dropped to zero and that the fuel temperature has either reached ambient
temperature or is below 30°C, whichever is the greater.

2. 2. Raise and support the vehicle. REFER to:

Lifting

(100-02 Jacking and Lifting,

Description and Operation).

3. 3. Remove the engine undershield.

4. 4. Remove the radiator undershield.