Ford S-Max
2.0 TDCi 88 kW/120 hp, S-Max II (CD340 2015-2019) / Galaxy III
Van Too Weak
120 hp in the big S-Max: reserves run dry with a full load.
Engine Weaknesses 7
Continental injectors with a faulty internal coating (vehicles built Feb–Sep 2019). The coating delaminates and blocks the injector. Ford service action: free injector replacement (Ford TSB-20-2335). Affected vehicles: Transit, Ranger, Focus, Mondeo, S-Max, Galaxy, Edge.
Symptoms: Hesitation, poor idle, power reduction, increased fuel consumption, limp mode
Faulty injectors generate excessive soot that prematurely clogs the DPF. On the high-output variant (190 hp), soot also blocks the low-pressure filter of the dual EGR system. Repair requires simultaneous replacement of injectors AND DPF (TSB-20-2335). Replacing the DPF alone does not resolve the issue long-term.
Symptoms: Fault codes P2002, P02EC, P02FA, check engine light, power reduction
The high-pressure pump on the 2.0 TDCi 132 kW typically fails from 150,000 km. Failed pumps can shed metal particles into the fuel system and damage injectors.
Symptoms: Poor or no start, severe power loss, fault codes P0087 (rail pressure too low).
The 2.0 EcoBlue uses a wet-belt drive to the oil pump. Coating wear generates fine particles that clog the oil pump strainer. Low oil pressure damages bearings, crankshaft, camshaft and turbocharger.
Symptoms: No early warning symptoms; when clogged: oil pressure warning, metallic knocking, turbocharger wear, in the worst case sudden engine failure
The intake port geometry of the 2.0 EcoBlue routes a disproportionate amount of EGR soot particles into the middle cylinders. Piston rings grind soot into the cylinder walls; from around 135,000 km compression loss is possible.
Symptoms: High fuel trim correction data, power loss, oil consumption, injector quantity fault codes, workshop finding: cylinder wall scoring in cylinders 2 and 3
The NOx sensor in the SCR exhaust aftertreatment system fails prematurely. Fault code P20EE is typical. AdBlue consumption increases measurably as the system reverts to a base map. Sensor replacement is relatively inexpensive.
Symptoms: Check engine light P20EE, increased AdBlue consumption, occasional no-start after many km
The variable turbine geometry actuator on the 2.0 TDCi 132 kW fails electrically, often due to connector corrosion or actuator motor wear. In many cases only the electronics are faulty.
Symptoms: Sudden power loss, engine in limp mode, boost pressure regulation fault codes.
Vehicle Weaknesses 7
The 1.5- and 2.0-litre EcoBoost engines in the S-Max II are susceptible to hairline cracks in the engine block, causing coolant loss and in the worst case engine damage. Particularly affected are model years before mid-2019.
Ford recalled over 200,000 Galaxy and S-Max vehicles in Europe because the original bolts securing the rear trailing arms can fracture from severe corrosion. If they break the rear axle can fail — acute accident risk.
Corrosion occurs at the rear axle of the S-Max II on track rod ends and axle bolts. Ford recalled affected vehicles. On untreated examples, fracture and loss of driving safety are a risk.
The adaptive headlight control unit in the S-Max II occasionally fails, disabling automatic beam levelling. The failure is listed as a common finding in TÜV reports.
On the Ford S-Max II, rust forms at the tailgate — particularly on lower folded edges and hinge holes — with increasing age. Tow bars are also affected, as corrosion protection around the mounting point often deteriorates.
The Sync 3 infotainment system freezes during temperature fluctuations or after extended standstill and needs to be restarted. Bluetooth connections drop and voice control responds unreliably, particularly on newer vehicles after OTA updates.
TÜV statistics and driver reports confirm above-average brake disc wear on the S-Max II at both front and rear axles. Brake hoses also become brittle with age, which can lead to loss of braking effect.
Reports & Tests
442 owner complaints filed with NHTSA (2015–2023). Most reported: Backup Camera/Sensors (145), Other (88), Electrical (61).