Ford S-Max - engine malfunction

doubledown

Hi all. Just a quick one for you.

I bought a used Ford S-Max about two weeks ago from a very established and reputable dealer in Terenure. 1.8 litre diesel, 08 plate, 80,000 miles approx on the clock, full service history, mint condition inside and out, 6 month warranty, brand new brakes and tyres and full valet. I drove it twice before buying and it ran like new. I also had mechanic friend give it the all clear.

However, a week later and the car would not start one morning. I switched on the ignition, waited for the coil light to go off but when I turned the key a light on the dash simply read ENGINE MALFUNCTION. The car had been running fine with zero issues. I tried a few times but the starter motor wasn't making a sound. But it wasn't the battery as the car still had full electrics. I waited a few minutes and tried again and it started fine. I took it for a run around the block and it seemed okay so I set off to IKEA with the family in tow. When we arrived half an hour later I noticed the fan was running when pulled into a parking space. I thought this was unusual as it was a very cold day (about 3 degrees) and we had been on the motorway the entire time. It went off after a few minutes.

On the return journey the car started without issue but the fan kicked in about halfway home and the engine temperature almost went into the red. I also experienced some power loss. I managed to get home and parked it up for the rest of the weekend.

I brought the car back to the dealer and explained what had happened. The car was fine for the whole journey there - typical.

Three days later and he tells me that every time they have taken the car out to test it there have been no issues and that there were no faults logged in the system. He has been very helpful and seems keen to get it resolved but we're baffled as to what it could be.

Anyone have any ideas? I want to get this resolved as my wife will be driving the car daily with my two young children. Thanks in advance.

CJhaughey

I wonder is the dealer trying to duck away from a problem.
The engine malfunction must have logged a fault or the message wouldn't have come on.
Check the wet belt has been done on the engine, if that fails there could be a big bill.

Tenzor07

A couple of thoughts:

Dealer could be using a generic fault reader, so may not pick up on Ford codes.
Bring it to a Ford main dealer and get them to test, and do a software reset also.
Or buy this: http://www.smaxownersclub.com/elm327.html

Try something like this: http://reviveturbocleaner.com/ Will help remove any soot build up in the Turbo.

doubledown

Tenzor07 wrote: »

A couple of thoughts:

Dealer could be using a generic fault reader, so may not pick up on Ford codes.
Bring it to a Ford main dealer and get them to test, and do a software reset also.
Or buy this: http://www.smaxownersclub.com/elm327.html

Try something like this: http://reviveturbocleaner.com/ Will help remove any soot build up in the Turbo.

To be fair to the dealer he is taking it to Ford today himself to see what they say. Thanks for the recommendations.

Larbre34

That engine is well known for and is at the critical mileage for dual mass flywheel failure.

Your reported starter issues are often the symptoms of such a problem - tiny pieces of metal migrating into the starter motor.

Have your paperwork sorted and your wits about you as it could be a return to dealer job. Its a hugely expensive fix otherwise.

doubledown

Larbre34 wrote: »

That engine is well known for and is at the critical mileage for dual mass flywheel failure.

Your reported starter issues are often the symptoms of such a problem - tiny pieces of metal migrating into the starter motor.

Have your paperwork sorted and your wits about you as it could be a return to dealer job. Its a hugely expensive fix otherwise.

Lovely...

Larbre34

Sorry. But better now than in a month or two, you are far more likely to get back your money and be no worse off, apart from the hassle.

shietpilot

Larbre34 wrote: »

That engine is well known for and is at the critical mileage for dual mass flywheel failure.

Your reported starter issues are often the symptoms of such a problem - tiny pieces of metal migrating into the starter motor.

Have your paperwork sorted and your wits about you as it could be a return to dealer job. Its a hugely expensive fix otherwise.

Bits of the flywheel going into the starter wouldn't make the starter not even attempt starting. You would hear rough starter sounds, slow disengagement etc.

It could even be as little as a bad battery connection/ground. Proper diagnostics will indicate what is wrong.

OldmanMondeo

Larbre34 wrote: »

tiny pieces of metal migrating into the starter motor.

Are you sure you not getting confused with the Transit? That was a major problem with them. DMF fail due to poor / slow starting, bad earths, poor battery all cause this. Injector troubles can also cause a DMF to fail.

Op, you said the temperature gauge went into the red? Is there coolant ok? Is the heating working alright?

doubledown

OldmanMondeo wrote: »

Are you sure you not getting confused with the Transit? That was a major problem with them. DMF fail due to poor / slow starting, bad earths, poor battery all cause this. Injector troubles can also cause a DMF to fail.

Op, you said the temperature gauge went into the red? Is there coolant ok? Is the heating working alright?

It shot into the red, stayed there for about five minutes and the dropped back down to normal. The fan was coming on even at the end of short trips. But the coolant level was fine, no drop or leak.

mullingar

I dont think these two faults are related at all.

Re starter motor, AFAIK this sits on the front of the engine, below the thermostat and it this is leaking it will drip onto the starter. Starters can also fail sue to wear and usually starts with intermittent operation. Also the key switch could be intermittent.

Re coolant system. If your system is air-locked it will cause similar problems but this usually goes out of most engines after a few miles of driving. Check the coolant level in the expansion bottle is between the max/min levels. How is the heating inside the car?

dr.fuzzenstein

Larbre34 wrote: »

That engine is well known for and is at the critical mileage for dual mass flywheel failure.

Your reported starter issues are often the symptoms of such a problem - tiny pieces of metal migrating into the starter motor.

Have your paperwork sorted and your wits about you as it could be a return to dealer job. Its a hugely expensive fix otherwise.

Clutch and DMF should do 250k km on them.
Sounds more like electrical fault. Coolant low and fan kicking in shouldn't make any difference. If it does overheat, it will say so on the dash.
Sounds like some electrical malady. Get a cheapo bluetooth dongle and Forscan on your phone (this will work for Android) and scan the car yourself.

doubledown

Hi all - quick update. They have had the car all week and checked it over from top to bottom. They brought it to Ford as well who thought it was more than likely a faulty thermostat so this has been replaced. They have given it a few runs and assure me that the problem has not reoccurred. Picking it up today so fingers crossed. Thanks again for all your advice and input.

doubledown

Update - It's September 2023, we still have the car, it has over 220,000 km on the clock and it's still running like a dream!