Ford S-Max

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 bi-turbo of the 2.0 EcoBlue 190 hp can fail to regulate boost correctly under high load (e.g. towing). Limp mode activates; fault code P2599 is typical.

Symptoms: Engine limp mode under full load, whistling on acceleration, limp mode activation, power loss

The oil bath timing belt deteriorates and clogs the oil pump strainer with debris. The engine dies from oil starvation — bearings, crankshaft, camshaft, and turbocharger are destroyed.

Symptoms: No warning: oil pressure drops, engine runs roughly, then total failure. Belt itself may appear visually intact.

The 2.0 EcoBlue turbocharger sometimes fails before 50,000 km. Cause: belt debris in the oil circuit or excessively long oil change intervals block oil supply to the turbo bearing.

Symptoms: Whistling noise on acceleration, noticeable power loss, blue smoke. Turbo warning light may be absent.

Design-related uneven distribution of EGR exhaust gas causes excessive soot ingestion into the middle cylinders. Soot particles cause abrasive wear via piston rings — compression loss and engine replacement.

Symptoms: Rough idle, elevated oil consumption, white or black smoke, high fuel trim correction values in fault memory.

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 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.

The 6-speed Powershift dual-clutch gearbox in the S-Max II is prone to clutch wear, juddering when pulling away, sticking in gears and limp mode activation. Repair costs are considerable.

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.