Ford Galaxy / Ford S-MAX. Manual - part 256

Numbers on the crankshaft main bearing caps specify where they should be installed. When
installing them, the crankshaft main bearing cap marked "1F" must be nearest the
transmission.

Axial play is restricted by means of two thrust plates on the crankshaft main bearing of
cylinder 1.

The thrust plates have lubricating grooves which must be pointing towards the main
bearing when installing them.

Oil pump

Description

Oil pump sprocket

Oil pump housing

Oil strainer

Pressure relief valve

Retaining bolts

Blanking plug

The oil pump is located on the front face of the engine and is housed inside the oil pan.

It is a rotor pump and is driven by the crankshaft via a short oil pump chain.

An oil pressure control valve is incorporated in the oil pump housing. It opens when the oil
pressure reaches about 8 bar.

Oil filter/oil cooler unit

Item

Part Number

Description

Oil filter housing

Oil cooler

The oil cooler is an oil/coolant heat exchanger.

The oil filter/oil cooler unit is located on the side of the cylinder block in line with cylinder 2.

The oil filter element has a blanking plug which seals off the drain hole in the oil filter
housing.

When changing the oil filter cartridge, the plug is removed with the oil filter cartridge. The
oil can return to the oil pan through the housing, so that no pollution can be caused by
leaking oil.

The oil filter/oil cooler unit is connected directly with the engine's coolant circuit by means
of an adapter and connecting hose.

Description

Oil pressure switch

The oil pressure switch is on the right-hand side, beside the oil/coolant heat exchanger.

The oil pressure switch monitors the minimum oil pressure of 0.5 bar. If the system does
not reach this pressure, the oil filter remains closed, for safety reasons.

Oil spray tubes

Item

Part Number

Description

Banjo bolts

Oil spray tubes

The piston skirts are cooled from below using oil from the oil spray tubes. The oil spray
tubes are secured in the cylinder block with banjo bolts.

The banjo bolts are connected to the engine oil circuit.

Valves are built into the banjo bolts, and from a minimum oil pressure of about 0.5 bar they
supply the oil spray tubes.

Item

Part Number

Engine - 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 - Engine

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

Diagnosis and Testing

Special Tool(s)

General Equipment

Materials

Specification

WSK-M2G349-A7

Inspection and Verification

1. 1. Verify the customer concern.

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

303-1056

Ford diagnostic equipment

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

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