Ford S-Max

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

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

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.

The high-pressure pump on the 1.8 TDCi fails frequently between 150,000 and 220,000 km. Metal debris contaminates the fuel system and injectors, often requiring the entire common-rail system to be renewed.

Symptoms: Engine dies suddenly, flashing glow plug light, poor throttle response, engine won't restart, blue smoke

The dual-mass flywheel (DMF) is a known wear point on Duratorq diesels. Rattling and drivetrain vibrations appear from around 150,000–200,000 km. Repair is typically combined with a full clutch kit (approx. 1,200 €).

Symptoms: Metallic rattling when releasing the clutch, vibrations at idle, grinding noise when pulling away

The 1.8 Duratorq TDCi injectors are damaged by biodiesel content and fuel contamination. Leaking injectors cause rough running and smoke. Metal swarf from the injection pump can contaminate all injectors.

Symptoms: Severe misfires at idle; black smoke; power loss; difficult cold start behaviour; fuel smell in cabin.

The rubber damper in the crankshaft pulley of the 1.8 TDCi wears from around 100,000 km and generates noise. Continued use risks the auxiliary belt being shed and failure of the alternator and power steering.

Symptoms: Ticking or knocking noise at idle from the auxiliary belt area, louder on cold start, vibration at idle

An overflowing windscreen washer reservoir damages the wiring harness that runs below it. Cable insulation is attacked by the fluid, which can lead to engine stalling, AC failure and fault code P0003.

The central locking on the S-Max WA6 is known to be fault-prone: doors open spontaneously or cannot be opened, particularly the tailgate. In the worst case doors open while driving.

According to TÜV reports, the S-Max WA6 frequently has suspension, steering and driveshaft issues flagged. Broken front springs and worn driveshaft CV boots are typical.

The TPMS tyre pressure sensors on the S-Max WA6 corrode at the valve stem and mounting, causing seal failure. In the worst case the valve can fracture and cause sudden pressure loss, especially at higher speeds.