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Ford Galaxy / Ford S-MAX. Manual - part 106

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 specification.

Faulty positive crankcase

ventilation (PCV) system.

Hoses or ventilation or

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

The PCV oil separator is

damaged. Oil can enter
the combustion chamber
through the intake
manifold.

CHECK if the PCV system is operating

correctly and repair as necessary.

Damaged gaskets or

mating surfaces.

Damaged cylinder head

gasket or warped mating
faces.

Worn valve stem oil seals.

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

CHECK the gaskets and mating surfaces

for damage.

Remove the cylinder head. CHECK the

condition of the mating faces and the
cylinder head gasket and CHECK the
evenness of the cylinder head and cylinder
block mating faces.

INSTALL new valve stem oil seals.

REFER to:

Valve Stem Seals

(303-01A

Engine - 2.0L Duratec-HE (107kW/145PS)
- MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4, Removal and
Installation).

Piston ring or cylinder

liner wear.

INSTALL new components as necessary.

Damaged cylinder liners

or excessive clearance of
engine components.

Piston
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

(303-03A Engine

Cooling - 2.0L Duratec-HE (107kW/145PS)
- MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, 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 battery cable

CHECK the battery, battery holder and

battery cable(s).
REFER to:

Specifications

(414-01 Battery,

Mounting and Cables, Specifications).

Starter motor or cables.

CHECK the starting system.

REFER to:

Starting System

(303-06A

Starting System - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4,
Diagnosis and Testing).

Engine cranks but
will not start.

Fuel tank is empty.

CHECK the fuel level.

Intake Air Distribution and

Filtering

CHECK the intake air system.

Engine management

CHECK the engine management system.

Ignition system

CHECK the ignition system.

Incorrect valve timing.

CHECK and adjust valve timing.

REFER to:

Crankshaft Pulley

(303-01C

Engine - 2.3L Duratec-HE (118kW/160PS)
- MI4, Removal and Installation).

Timing chain or timing

chain sprockets damaged
or broken

CHECK the timing chain and timing chain

sprockets. INSTALL new components as
necessary.
REFER to:

Timing Chain

(303-01C Engine -

2.3L Duratec-HE (118kW/160PS) - MI4,
Removal and Installation).

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

Fuel system

CHECK the fuel system.

Intake Air Distribution and

Filtering

CHECK the intake air system.

Restricted exhaust

system.

CHECK the exhaust system.

REFER to:

Exhaust System - 2.0L Duratec-

HE (107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4

(309-00A

Exhaust System - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Description and
Operation).

Engine management

CHECK the engine management system.

Ignition system is faulty

CHECK the ignition system.

Incorrect valve timing,

timing chain or timing
chain sprockets damaged

CHECK and adjust valve timing. INSTALL

new components as necessary. REFER to:
(303-01C Engine - 2.3L Duratec-HE
(118kW/160PS) - MI4)

Crankshaft Pulley

(Removal and

Installation),

Timing Chain

(Removal and

Installation).

Incorrect ignition timing

CHECK the electronic engine controls.

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: (303-01C Engine -
2.3L Duratec-HE (118kW/160PS) - MI4)

Crankshaft Pulley

(Removal and

Installation),

Timing Chain

(Removal and

Installation).

Noisy running,
misfiring,

Incorrect fuel

DETERMINE which type of fuel was last

put in the tank (note the country specific

Oil Leaks - Engine

NOTE: Before renewing gaskets or oil seals, make sure that the cause of the fault is
clearly established.

If the oil leak cannot be identified clearly by a visual inspection, carry out an 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

observe this instruction can lead to injuries.

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

4. 4. Stop the engine.

NOTE: If no leak is found, perform a road test. Drive the vehicle under different loads and
then re-check the engine for leaks.

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

backfiring or
knocking

fuel specifications).

Water in fuel or fuel

contaminated.

CHECK the fuel system for water or other

contamination.

Incorrect valve timing,

timing chain or timing
chain sprockets damaged

CHECK and adjust valve timing. INSTALL

new components as necessary. REFER to:
(303-01C Engine - 2.3L Duratec-HE
(118kW/160PS) - MI4)

Crankshaft Pulley

(Removal and

Installation),

Timing Chain

(Removal and

Installation).

Noisy running or
valve train noise

Valve clearance too large

due to faulty valve tappets
or worn valve train
components.

ADJUST valve clearance.

REFER to:

Valve Clearance Adjustment

(303-01C Engine - 2.3L Duratec-HE
(118kW/160PS) - MI4, General
Procedures).

Timing chain damaged.

INSTALL a new timing chain.

REFER to:

Timing Chain

(303-01C Engine -

2.3L Duratec-HE (118kW/160PS) - MI4,
Removal and Installation).

Timing chain incorrectly

tensioned

CHECK the timing chain tension. INSTALL

a new timing chain if required.
REFER to:

Timing Chain

(303-01C Engine -

2.3L Duratec-HE (118kW/160PS) - MI4,
Removal and Installation).

Noisy running or
engine noise

Engine components
Piston
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

(303-01C Engine

- 2.3L Duratec-HE (118kW/160PS) - MI4,
Specifications).

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

Measure the compression pressure

1. 1. Remove the central junction box cover.

2. 2. Detach the central junction box (CJB).

3. 3. Open the CJB and remove fuse 23 - fuel pump relay.

NOTE: The engine will start, run for a few seconds and then stop.

4. 4. Start the engine.

5. 5. Detach the engine cover.

Content .. 104 105 106 107 ..