Ford S-Max WA6

1.6 TDCi 85 kW/115 hp, S-Max I facelift (WA6 2010-2015)

• !! Injector Seal 'Black Death' Failure from 100,000 km

  The copper sealing washers at the injector seat fail and allow soot to enter the engine oil. The soot blocks the mesh filter in the turbo oil feed. This is the primary cause of turbocharger damage on this engine. Replacing all injector seals is a known maintenance item.

  Symptoms: Diesel smell inside the cabin, black deposits around injectors, smoke from the engine bay, subsequent turbocharger damage
  200–600 $
  Ad Ford 1.6 TDCi fuel injectorgasket Kupferwascher1.6 TDCi fuel injectorn-Kupferdichtring
• !! Turbocharger Failure from Oil Starvation from 130,000 km

  Soot from leaking injector seals blocks the fine mesh filter in the turbo oil feed (banjo bolt). Below 0.8 bar oil pressure the turbocharger fails. A complete repair includes the turbo, oil sump, oil strainer, oil filter housing and intercooler. Costs run to £1,300–£2,200.

  Symptoms: Whistling from the turbo area, power loss, blue smoke clouds, oil in the intake tract
  1,500–2,500 $
  Ad Ford 1.6 TDCi turbocharger Garrett GT151.6 TDCi Turbo oil feed line Hohlschraube
• !! High-Pressure Pump Metal Debris and Failure from 160,000 km

  At higher mileages the high-pressure pump wears internally and leaves metal swarf in the fuel filter. Swarf can damage injectors. The pump can fail suddenly on the motorway.

  Symptoms: Golden metal swarf in the diesel filter housing, engine drops into limp mode or stalls under full load, difficult cold starting.
  800–3,000 $
  Ad high-pressure pump Ford 2.0 TDCi Duratorqinjection pump Ford Mondeo 2.0 TDCi 3S7Q-9B395-AAhigh-pressure pump Ford Galaxy S-Max 2.0 TDCi 9044A100Ahigh-pressure pump seal 2.0 TDCi Delphi 7190-266

+ 6 more engine weaknesses + vehicle weaknesses

1.8 TDCi 92 kW/125 hp, S-Max I (WA6 2006-2010)

• !! Injector seal: "Black Death" failure from 120,000 km

  The copper sealing washers at the injector seat fail under pressure and heat. Combustion gases blow past the injector and bake black, tar-like carbon onto the injector boss. Seized injectors require specialist tools for removal; the cylinder head sealing face can be damaged.

  Symptoms: Black deposits around injectors, diesel smell, rough running, cylinder pressure loss
  200–800 $
  Ad Ford 1.8 TDCi fuel injectorgasket Kupfer1.8 TDCi fuel injectorn-Kupferdichtring Focus Mondeo
• !! Turbocharger failure from 150,000 km

  Turbocharger damage from oil starvation due to blocked oil supply passages, or from soot ingress via leaking injector seals. Repair costs are significant, as the sump and cooler must also be cleaned in addition to the turbo.

  Symptoms: Whistling or grinding from the turbo area, severe power loss, oil entering the intake tract, blue exhaust smoke
  900–2,200 $
  Ad Ford 1.8 TDCi turbochargerTurbo 1.8 TDCI Mondeo Focus
• !! Seized Injectors — Cannot Be Extracted from 100,000 km

  Injectors in the Transit 2.0 EcoBlue corrode into the cylinder head and cannot be removed without Ford special tool 303-1706. Cylinder head removal is blocked until injectors are extracted.

  Symptoms: No driving symptoms; problem arises during maintenance or repair; injector will not pull out despite great force.
  800–3,000 $
  Ad injector extraction tool Transit 2.0 EcoBlue303-1706 Ford Transit injector tool

+ 4 more engine weaknesses + vehicle weaknesses

2.0 TDCi 103 kW/140 hp, S-Max I (WA6 2006-2010)

• !! Injector Wear and Leaks from 150,000 km

  Injectors on the 2.0 TDCi family show measurable wear from around 150,000 km. Leaking copper sealing washers allow combustion gases to escape ('Black Death'). Replacing one injector soon necessitates replacing all, as wear state is similar across the set.

  Symptoms: Rough running, diesel knock, black soot deposits around injectors, power loss
  300–1,500 $
  Ad Ford 2.0 TDCi fuel injector Siemens Continental2.0 TDCI fuel injector Mondeo Focus S-Max
• !! High-Pressure Pump Metal Contamination and Failure from 160,000 km

  At higher mileage the high-pressure pump wears internally and leaves metal swarf in the fuel filter. The swarf can damage injectors. The pump can fail suddenly on the motorway.

  Symptoms: Golden metal swarf in the diesel filter housing, engine drops into limp mode or stalls at full load, difficult cold start.
  800–3,000 $
  Ad high-pressure pump Ford 2.0 TDCi Duratorqinjection pump Ford Mondeo 2.0 TDCi 3S7Q-9B395-AAhigh-pressure pump Ford Galaxy S-Max 2.0 TDCi 9044A100AHP pump seal 2.0 TDCi Delphi 7190-266
• !! Timing Belt Early Failure — Interval Too Long from 100,000 km

  Ford specifies 200,000 km or 10 years as the change interval (automatic: 100,000 km). A belt with 15 cm of missing teeth has been documented at 99,000 km. Belt failure destroys rocker arms and the camshaft.

  Symptoms: No warning on belt failure — abrupt engine shutdown on motorway, loud impact from engine.
  500–900 $
  Ad timing belt kit Ford 2.0 TDCi Duratorqtiming belt Ford Mondeo S-Max 2.0 TDCitiming belt water pump kit Ford Focus 2.0 TDCitiming tool Ford 2.0 TDCi 2.2 TDCi

+ 4 more engine weaknesses + vehicle weaknesses

2.0 TDCi 120 kW/163 hp, S-Max I facelift (WA6 2010-2015)

• !! Injector Wear and Leaks from 150,000 km

  Injectors on the 2.0 TDCi family show measurable wear from around 150,000 km. Leaking copper sealing washers allow combustion gases to escape ('Black Death'). Replacing one injector soon necessitates replacing all, as wear state is similar across the set.

  Symptoms: Rough running, diesel knock, black soot deposits around injectors, power loss
  300–1,500 $
  Ad Ford 2.0 TDCi fuel injector Siemens Continental2.0 TDCI fuel injector Mondeo Focus S-Max
• !! Oil Bath Belt Clogs Oil Pump Strainer from 100,000 km

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

  Symptoms: No prior warning: oil pressure drops, engine runs rough, then total destruction. Belt itself may look intact visually.
  1,900–2,300 $
  Ad timing belt EcoBlue 2.0 oil bathoil pump drive belt EcoBluetiming belt kit Ford EcoBlue 2.02011555 Ford oil bath drive belt EcoBlue
• !! Premature Turbocharger Failure from Oil Starvation from 60,000 km

  The 2.0 EcoBlue turbocharger can fail before 50,000 km. Cause: belt debris in the oil circuit or overdue oil change intervals clog the oil feed to the turbo bearing.

  Symptoms: Whistling on acceleration, noticeable power loss, blue smoke. Turbo warning light may not illuminate.
  1,400–2,500 $
  Ad turbocharger Ford EcoBlue 2.0turbocharger Ford Focus Mk4 2.0 EcoBlueoil feed line turbocharger EcoBlue 2.0

+ 7 more engine weaknesses + vehicle weaknesses

2.0 TDCi 103 kW/140 hp, S-Max I facelift (WA6 2010-2015) / Galaxy II facelift

• !! Injector Wear and Leaks from 150,000 km

  Injectors on the 2.0 TDCi family show measurable wear from around 150,000 km. Leaking copper sealing washers allow combustion gases to escape ('Black Death'). Replacing one injector soon necessitates replacing all, as wear state is similar across the set.

  Symptoms: Rough running, diesel knock, black soot deposits around injectors, power loss
  300–1,500 $
  Ad Ford 2.0 TDCi fuel injector Siemens Continental2.0 TDCI fuel injector Mondeo Focus S-Max
• !! High-Pressure Pump Metal Debris and Failure from 160,000 km

  At higher mileages the high-pressure pump wears internally and leaves metal swarf in the fuel filter. Swarf can damage injectors. The pump can fail suddenly on the motorway.

  Symptoms: Golden metal swarf in the diesel filter housing, engine drops into limp mode or stalls under full load, difficult cold starting.
  800–3,000 $
  Ad high-pressure pump Ford 2.0 TDCi Duratorqinjection pump Ford Mondeo 2.0 TDCi 3S7Q-9B395-AAhigh-pressure pump Ford Galaxy S-Max 2.0 TDCi 9044A100Ahigh-pressure pump seal 2.0 TDCi Delphi 7190-266
• !! Premature Timing Belt Failure — Interval Too Long from 100,000 km

  Ford specifies 200,000 km or 10 years as the replacement interval (automatic: 100,000 km). A belt with 15 cm of missing teeth has been documented at only 99,000 km. Belt failure destroys rocker arms and the camshaft.

  Symptoms: No prior warning on belt snap — sudden engine stall on the motorway, loud banging from the engine.
  500–900 $
  Ad timing belt kit Ford 2.0 TDCi Duratorqtiming belt Ford Mondeo S-Max 2.0 TDCitiming belt water pump kit Ford Focus 2.0 TDCitiming tool set Ford 2.0 TDCi 2.2 TDCi

+ 4 more engine weaknesses + vehicle weaknesses

2.2 TDCi 129 kW/175 hp, S-Max I (WA6 2006-2010)

• !! Injector Failure and Piston Damage from 150,000 km

  Failed injectors cause over-fuelling of individual cylinders and piston damage (crack in piston crown). The 2.2L Duratorq has a high rate of engine failures from this damage pattern, especially on early build years. Ford recommends premium diesel for this engine.

  Symptoms: Knocking sounds, severe power loss, white or black smoke, engine failure
  500–8,000 $
  Ad Ford 2.2 TDCi injector2.2 TDCi injector Mondeo Transit Ranger
• !! Oil Pump Failure (Ranger 2.2) from 180,000 km

  On the Ranger 2.2 TDCi the oil pump can fail causing immediate pressure loss. The result is crankshaft bearing and turbocharger damage. Unusual noises from the engine bay are the first sign.

  Symptoms: Knocking from engine, oil pressure warning light, power loss, turbo noise
  1,500–6,000 $
  Ad Ford 2.2 TDCi oil pump Ranger2.2 TDCi oil pump Transit Ranger
• !! High-Pressure Pump Failure from 150,000 km

  The high-pressure pump of the 2.2 Duratorq TDCi can fail. Metal debris from the pump contaminates the entire injection system and damages all injectors. Repair requires pump, all injectors and system flushing.

  Symptoms: Sudden power loss; engine won't start or stalls; fuel pressure too low per OBD; smoke; black residue in fuel system.
  1,500–5,000 $
  Ad Ford 2.2 TDCi high-pressure pumpQ4WA high-pressure pump1520296Duratorq 2.2 injection pump

+ 4 more engine weaknesses + vehicle weaknesses

2.2 TDCi 147 kW/200 hp, Mondeo III facelift (BA7 2010-2014) / S-Max facelift

• !! Injector Failure and Piston Damage from 150,000 km

  Failed injectors cause over-fuelling of individual cylinders and piston damage (crack in piston crown). The 2.2L Duratorq has a high rate of engine failures from this damage pattern, especially on early build years. Ford recommends premium diesel for this engine.

  Symptoms: Knocking sounds, severe power loss, white or black smoke, engine failure
  500–8,000 $
  Ad Ford 2.2 TDCi injector2.2 TDCi injector Mondeo Transit Ranger
• !! Oil Pump Failure (Ranger 2.2) from 180,000 km

  On the Ranger 2.2 TDCi the oil pump can fail causing immediate pressure loss. The result is crankshaft bearing and turbocharger damage. Unusual noises from the engine bay are the first sign.

  Symptoms: Knocking from engine, oil pressure warning light, power loss, turbo noise
  1,500–6,000 $
  Ad Ford 2.2 TDCi oil pump Ranger2.2 TDCi oil pump Transit Ranger
• !! High-Pressure Fuel Pump: Metal Wear and Failure from 160,000 km

  At higher mileages the high-pressure pump wears internally and deposits metal swarf in the fuel filter. Swarf can damage injectors. The pump can fail suddenly on a motorway.

  Symptoms: Golden metal swarf in the diesel filter housing, engine drops into limp mode or stalls at full load, difficult cold start.
  800–3,000 $
  Ad high-pressure fuel pump Ford 2.0 TDCi Duratorqinjection pump Ford Mondeo 2.0 TDCi 3S7Q-9B395-AAhigh-pressure fuel pump Ford Galaxy S-Max 2.0 TDCi 9044A100Agasket high-pressure fuel pump 2.0 TDCi Delphi 7190-266

+ 4 more engine weaknesses + vehicle weaknesses

2.2 TDCi 147 kW/200 hp, S-Max I facelift (WA6 2010-2015) / Galaxy II facelift

• !! Injector Failure and Piston Damage from 150,000 km

  Failed injectors cause over-fuelling of individual cylinders and piston damage (crack in piston crown). The 2.2L Duratorq has a high rate of engine failures from this damage pattern, especially on early build years. Ford recommends premium diesel for this engine.

  Symptoms: Knocking sounds, severe power loss, white or black smoke, engine failure
  500–8,000 $
  Ad Ford 2.2 TDCi injector2.2 TDCi injector Mondeo Transit Ranger
• !! Oil Pump Failure (Ranger 2.2) from 180,000 km

  On the Ranger 2.2 TDCi the oil pump can fail causing immediate pressure loss. The result is crankshaft bearing and turbocharger damage. Unusual noises from the engine bay are the first sign.

  Symptoms: Knocking from engine, oil pressure warning light, power loss, turbo noise
  1,500–6,000 $
  Ad Ford 2.2 TDCi oil pump Ranger2.2 TDCi oil pump Transit Ranger
• !! Timing Chain Stretch from 120,000 km

  The 1.5 EcoBoost in the Kuga II shows frequent premature timing chain stretch between 100,000–150,000 km. Chain jump leads to piston-to-valve contact and total engine failure.

  Symptoms: Rattling on cold start, engine warning light, misfires, in the worst case sudden engine failure.
  1,500–4,000 $
  Ad timing chain 1.5 EcoBoost Kugachain tensioner Ford Kuga II

+ 4 more engine weaknesses + vehicle weaknesses

1.6 EcoBoost SCTi 118 kW/160 hp, S-Max I facelift (WA6 2010-2015)

• !! Cylinder Head Cracks — Recall Issue from 80,000 km

  The 1.6 EcoBoost JTWA (S-Max MK1 FL, Galaxy MK2 FL) is also affected by cylinder head cracks from overheating. The Ford recall on cooling system monitoring applies to this variant as well.

  Symptoms: Coolant loss, white exhaust smoke, rising engine temperature
  1,500–4,000 $
  Ad Ford 1.6 EcoBoost cylinder head JTWAFord S-Max 1.6 EcoBoost cylinder head
• !! PowerShift Gearbox Judder on Take-Off from 80,000 km

  The PowerShift dual-clutch gearbox in combination with the 1.6 EcoBoost JTWA exhibits the well-known shudder on take-off. Gearbox software updates and oil changes every 60,000 km are essential.

  Symptoms: Judder on take-off, slipping gearchanges at low speeds, gearbox warning light
  500–3,000 $
  Ad Ford PowerShift transmission fluid6DCT450 PowerShift Servicesatz Ford
• !! Turbocharger Wear from 140,000 km

  The 1.6 EcoBoost JTWA turbocharger wears prematurely when maintenance intervals slip. In the S-Max/Galaxy under heavy load with full payload, wear accelerates.

  Symptoms: Whistling turbo noise, declining boost pressure, blue smoke
  800–2,000 $
  Ad Ford 1.6 EcoBoost turbochargerFord Galaxy S-Max 1.6 EcoBoost turbo JTWA

+ 4 more engine weaknesses + vehicle weaknesses

2.0 Duratec 107 kW/145 hp, S-Max I (WA6 2006-2010)

• !! Intake Throttle Plate Risk (Galaxy/S-Max) from 80,000 km

  The 2.0L Duratec-HE AOWA (S-Max MK1, Galaxy MK2) may show the known throttle plate problem on early intake manifolds. On the heavier family van, listen out for engine noises especially carefully.

  Symptoms: Rattling from the intake, sudden power loss, possible engine damage
  200–2,000 $
  Ad Ford 2.0 Duratec AOWA intake manifoldFord Galaxy S-Max 2.0 Duratec swirl flap
• !! Timing Chain Tensioner Wearing Out from 160,000 km

  The chain tensioner on the 2.0 Duratec-HE AOWA wears at long oil change intervals. Watch for cold start rattling at mileages over 150,000 km.

  Symptoms: Metallic rattling on cold start, stops after warm-up
  300–700 $
  Ad Ford 2.0 Duratec AOWA chain tensionerFord S-Max 2.0 Duratec timing chain tensioner
• !! Increased Oil Consumption from 150,000 km

  At high mileages the 2.0 Duratec-HE AOWA in the Galaxy/S-Max shows increased oil consumption from degrading valve stem and piston ring seals.

  Symptoms: Bluish smoke, oil level drops between changes
  300–800 $
  Ad Ford 2.0 Duratec AOWA valve stem sealsFord Galaxy S-Max 2.0 Duratec oil consumption

+ 3 more engine weaknesses + vehicle weaknesses

2.0 EcoBoost 176 kW/240 hp PowerShift, Mondeo III facelift / S-Max facelift

• !! Hairline Cracks in Engine Block (Older Models) from 100,000 km

  The 2.0L EcoBoost TPBA (Mondeo MK4 FL) can be affected by hairline cracks in the engine block that Ford did not address until 2019. Check carefully for coolant loss before purchase.

  Symptoms: Dropping coolant level, rough cold start, white exhaust smoke
  3,000–7,000 $
  Ad Ford 2.0 EcoBoost engine block TPBAengine block Ford Mondeo 2.0 EcoBoost
• !! PowerShift Gearbox Judder from 80,000 km

  The PowerShift dual-clutch gearbox combined with the 2.0 EcoBoost TPBA shows the well-known pull-away judder. Gearbox oil change every 60,000 km is mandatory.

  Symptoms: Judder on pull-away or at low speeds, slipping gears
  500–3,000 $
  Ad Ford PowerShift gearbox oil 2.0 EcoBoost6DCT450 service kit Ford
• !! Turbocharger Wear from 160,000 km

  The turbocharger on the 2.0 EcoBoost TPBA shows increased bearing wear when oil change intervals are exceeded or from oil dilution. At 150,000+ km watch for turbo noises.

  Symptoms: Whistling turbo noise, dropping boost pressure, bluish smoke
  1,000–2,500 $
  Ad Ford 2.0 EcoBoost turbocharger TPBAFord Mondeo 2.0 EcoBoost turbocharger

+ 3 more engine weaknesses + vehicle weaknesses

2.3 Duratec 119 kW/161 hp, S-Max I (WA6 2006-2010)

• !! Intake Swirl Flap Issue (S-Max) from 80,000 km

  The 2.3L Duratec-HE SEWA (S-Max MK1, Galaxy MK2) can, like other Duratec-HE engines, be affected by loose intake throttle flaps.

  Symptoms: Rattling from the intake tract, potential engine damage
  200–2,000 $
  Ad Ford 2.3 Duratec SEWA intake manifoldFord S-Max Galaxy 2.3 Duratec swirl flap
• !! Connecting Rod Bearing Damage at High Mileage from 120,000 km

  The 2.3 Duratec-HE can develop connecting rod bearing failure, documented in one case at 122,000 km. The cause is reportedly overly soft bearing shells from manufacturing. Less common in the S-Max than the Maverick, but documented.

  Symptoms: Deep knocking from the lower engine block; noise intensifies under load; in the worst case a total write-off.
  1,500–5,000 $
  Ad Ford 2.3 Duratec connecting rod bearingsSEWA connecting rod bearingsDuratec HE 2.3 bearing shells
• !! Increased Oil Consumption from 150,000 km

  The 2.3 Duratec-HE SEWA shows increased oil consumption at high mileages. In the heavier S-Max/Galaxy with more load cycles, valve stem seal wear accelerates.

  Symptoms: Blue smoke on cold start, oil level dropping between changes
  400–1,000 $
  Ad Ford 2.3 Duratec SEWA valve stem sealsoil consumption repair kit Ford S-Max 2.3 Duratec

+ 3 more engine weaknesses + vehicle weaknesses

2.5T 5-cylinder 162 kW/220 hp, S-Max I (WA6 2006-2010)

• !! Turbocharger Wear on the Five-Cylinder from 130,000 km

  The 2.5L Duratec-ST HUWA (S-Max Mk1, Mondeo Mk4 ST) with 220 hp puts the turbocharger under heavy load. Bearing-wear oil leaks and falling boost pressure are known from 130,000 km.

  Symptoms: Whistling from the turbo, boost pressure drop, blue smoke at high revs
  1,200–3,000 $
  Ad Ford 2.5 Duratec ST HUWA turbochargerFord Mondeo ST 2.5 turbocharger
• !! Timing Belt — Long Neglected Change from 180,000 km

  The 2.5 Duratec-ST has a timing belt with a 200,000 km or 10-year change interval. Used cars often have no documented evidence of this service. A snapped belt causes immediate valvetrain destruction.

  Symptoms: Normally no warning; on a very old belt occasional faint rattle; after snap: immediate engine stop and destruction.
  600–1,500 $
  Ad Ford 2.5 Duratec-ST timing belttiming beltsatz HUWAVolvo B5254T timing belt
• !! Fuel System Issues — Hesitation at Part-Throttle from 120,000 km

  The 2.5 Duratec-ST shows hesitation at part-throttle at higher mileages from fouled injectors or a faulty fuel pressure regulator.

  Symptoms: Hesitation at 1,500–2,500 rpm, rough idle, poor throttle response
  300–900 $
  Ad Ford 2.5 Duratec ST fuel injectornKraftstoffdruckregler Ford Mondeo ST 2.5 HUWA

+ 4 more engine weaknesses + vehicle weaknesses