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Ford Galaxy / Ford S-MAX. Manual - part 257

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. REFER to:

Specifications

(303-01F 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,
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

(303-08D Engine

Emission Control - 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).

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. REFER to:

Cylinder Head

(303-01F 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, 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

(303-01F 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, 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

Cooling system

Check the cooling system components.

consumption

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
crank

Battery or cables.

CHECK the battery, bracket and cables.

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

(310-01C Fuel Tank and Lines - 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).

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

(303-07D Glow Plug 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, Removal and
Installation).

Engine management

system.

CHECK the engine management system.

Incorrect valve timing.

CHECK and adjust the valve timing. REFER

to:

Timing Belt

(303-01F 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, 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

(303-01F

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,
Removal and Installation).

Very poor power
output or fuel
consumption too
high or engine

Fuel charging system.

CHECK the fuel charging system. REFER to:

Fuel Charging and Controls

(303-04E Fuel

Charging and Controls - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi

running rough.

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

Engine intake air system.

CHECK the intake air system.

Exhaust system blocked.

CHECK the exhaust system. REFER to:

Exhaust System

(309-00E Exhaust 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, Description
and Operation).

Engine management

system.

CHECK the engine management system.

Turbocharger.

CHECK the 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, 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

(303-01F 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, Removal and
Installation).

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

(303-01F

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,
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

(303-01F 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, 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

(303-01F 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, Removal
and Installation).

Timing belt or timing

chain damaged.

INSTALL a new timing belt or timing chain.

REFER to:

Timing Belt

(303-01F Engine - 2.0L

Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) - DW/2.0L

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.

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.

Duratorq-TDCi (103kW/140PS) - DW,
Emission Requirements: Stage IV, 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

(303-01F 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, 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

(303-01F

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,
Specifications).

Content .. 255 256 257 258 ..