Ford Galaxy / Ford S-MAX. Manual — part 221

specification.

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-

08C Engine Emission Control - 1.8L
Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS)
- Lynx, Diagnosis and Testing).

*

Turbocharger seals.

*

INSTALL a new turbocharger.

REFER to:

Turbocharger

(303-04J Fuel

Charging and Controls - Turbocharger -
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, 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. 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

(303-01E

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

(303-03D

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

Battery or cables.

*

CHECK the battery, bracket and cables.

REFER to: Battery (414-01, Diagnosis
and Testing).

*

Starter motor or cables.

*

CHECK the starting system.

REFER to: Starting System (303-06,
Diagnosis and Testing).

*

Engine cranks but
will not start

Fuel tank is empty.

*

CHECK the fuel level.

*

Water in fuel (only diesel

engine).

*

Drain the water from the fuel system.

*

Fuel filter blocked.

*

INSTALL a new fuel filter.

*

Engine intake air system.

*

CHECK the intake air system.

REFER to: Intake Air Distribution and
Filtering (303-12, Diagnosis and Testing).

*

Glow plug faulty (only diesel

engine).

*

CHECK the glow plugs. INSTALL new

glow plugs as necessary.
REFER to: Glow Plug System (303-07,
Diagnosis and Testing).

*

Engine management

system.

*

CHECK the engine management system.

REFER to: Electronic Engine Controls -
1.8L Duratorq-TDCi (Lynx) Diesel (303-
14, Diagnosis and Testing).

*

Incorrect valve timing.

*

CHECK and adjust the valve timing.

REFER to: Valve Clearance Adjustment
(303-01, General Procedures).

*

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 (303-01, Removal
and Installation).

*

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

Fuel system.

*

CHECK the fuel system.

REFER to: Turbocharger (303-04,
Diagnosis and Testing).

*

Engine intake air system.

*

CHECK the intake air system.

REFER to: Intake Air Distribution and
Filtering (303-12, Diagnosis and Testing).

*

Exhaust system blocked.

*

CHECK the exhaust system.

REFER to: Exhaust System (309-00,
Description and Operation).

*

Engine management

system.

*

CHECK the engine management system.

REFER to: Electronic Engine Controls -
1.8L Duratorq-TDCi (Lynx) Diesel (303-
14, Diagnosis and Testing).

*

Turbocharger.

*

CHECK the turbocharger.

REFER to: Turbocharger (303-04,
Diagnosis and Testing).

*

Incorrect valve timing.

Timing belt/timing sprocket
or pulley/sprocket damaged.

*

CHECK and adjust valve timing.

REFER to: Timing Belt (303-01, Removal
and Installation).

*

Ignition timing incorrect

(only petrol engines).

*

CHECK the electronic engine controls.

REFER to: Electronic Engine Controls -
1.8L Duratorq-TDCi (Lynx) Diesel (303-
14, Diagnosis and Testing).

*

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 (303-01, Removal
and Installation).

*

Noisy running,

Incorrect fuel

*

DETERMINE which type of fuel was last

*

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.

WARNING: Vehicles with manual transaxle, shift the transaxle into Neutral. Failure to

follow this instruction may result in personal injury.

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.

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.

misfiring,
backfiring or
knocking

put in the tank (note the country specific
fuel specifications).

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 (303-01, 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 or

adjust the valve clearance.
REFER to: Valve Clearance Adjustment
(303-01, General Procedures).

*

Timing belt or timing chain

damaged.

*

INSTALL a new timing belt or timing

chain.
REFER to: Timing Belt (303-01, 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 (303-01, 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 (211-00,
Specifications).

*

Measure the compression pressure

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 worldwide diagnostic system (WDS) 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.

Measure the compression pressure (Engine - 1.8L Duratorq-TDCI (Kent) Diesel)

WARNINGS:

Do not smoke or carry lighted tobacco or open flame of any type when working on or

near any fuel related components. Highly flammable mixtures are always present and can
ignite. Failure to follow these instructions may result in personal injury.

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.

1. 1. Using datalogger in

worldwide diagnostic system (WDS)

, 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. Open the central junction box (CJB) and remove the glow plug relay.

3.

NOTE: The engine upper cover is held in place by 4 ball clips. The ball clips are not
vertical, but are angled backwards by approximately 20 degrees.

3. Location of the engine upper cover retaining clips.