Practical 7-seater family MPV popular for its spacious interior and driving dynamics. The 2.0 TDCi engine is a PSA-Ford joint development known for decent performance and reasonable fuel economy (35-44 MPG real-world). Main concerns center around diesel-specific issues: DPF blockage from short journeys, dual mass flywheel wear at 80,000-120,000 km, turbo actuator sticking, and timing belt stretch causing cold start rattle. Electrical gremlins common especially with battery drain and steering rack debris contamination on early models. Parts are widely available and moderately priced. Avoid Powershift automatic if possible - manual gearbox is significantly more reliable.
Heavy vibrations, rattling at idle, difficulty shifting gears · more· less
DMF failure is one of the most common high-cost repairs on the S-Max 2.0 TDCi. Symptoms include vibrations through the clutch pedal, metallic rattling at idle that disappears when clutch is depressed, heavy knocking on overrun, and difficulty selecting gears. Typically occurs between 80,000-120,000 km but can fail earlier with aggressive driving or frequent towing. Ford dealers charge €1,200-€1,400 for DMF and clutch replacement. Independent garages can do the job for €900-€1,100. Always replace clutch and slave cylinder at the same time since the gearbox must be dropped regardless. Some owners opt for single-mass conversion kits which are more robust but slightly noisier.
DPF blockage and regeneration failure€250 - €2,500
Warning light, loss of power, engine cuts to limp mode · more· less
The DPF is designed to last 120,000-180,000 km but frequently blocks earlier if the car is used mainly for short trips. Common root causes include failed fuel vaporizer (€300-400 repair), blocked differential pressure sensor rubber hoses (fail from heat), and insufficient regeneration cycles. Symptoms include dashboard warning lights, loss of power, and fuel dilution in engine oil (check oil level - if over max, diesel has mixed in). Professional DPF cleaning costs €200-400 and can restore function. DPF replacement costs €1,500-€2,500 including labor. Prevention: drive at constant highway speed for 20+ minutes monthly, use premium diesel, avoid only short trips. If DPF light appears, drive immediately on motorway at 2,500+ RPM for 15-20 minutes to complete regeneration.
Timing chain tensioner wear€1,000 - €2,200
Rattle on cold start lasting 1-30 seconds before disappearing · more· less
The EA211-based 2.0 TDCi uses a timing chain (not belt) but tensioner issues persist. The tensioner has a release valve that weakens over time, allowing oil pressure to bleed off overnight. This causes distinctive rattling for 1-30 seconds on cold start as the chain is momentarily loose. Typically occurs between 60,000-100,000 km. If rattle lasts more than a few seconds, chain has stretched and guides/sprockets are wearing. Complete replacement of chain, guides, tensioner, and sprockets costs €1,000-€2,200. VW has released updated tensioner parts. Ignoring this issue can lead to chain skip and catastrophic valve-to-piston contact requiring engine rebuild. The rattling is your early warning - act on it before it becomes constant.
Turbocharger failure€1,200 - €2,000
Blue smoke, loss of power, high oil consumption · more· less
Turbo failures typically occur after 150,000-200,000 km but can happen earlier. Common causes include oil starvation from blocked oil feed pipes, carbon buildup in actuator mechanism from gentle driving, and metal contamination from failed oil pump. Symptoms: sudden loss of power, blue exhaust smoke, increased oil consumption, fault code P0299 (turbo underboost). If turbo bearing breaks up, the system must be thoroughly cleaned - this includes oil flushes, sump replacement, oil filter housing, vacuum pump check, and intercooler flush. Complete dealer repair costs €1,800-€2,000. Remanufactured turbo units cost €600-€800 plus €400-€600 labor at independent garages. Prevention: use quality oil, change oil regularly, avoid shutting down immediately after hard driving, occasionally drive spiritedly to prevent actuator sticking.
Turbo actuator sticking€500 - €1,200
EPC light, limp mode, loss of boost pressure · more· less
The turbo actuator mechanism sticks from carbon buildup if the car is driven too gently or only for short trips. Symptoms include EPC warning light and sudden limp mode activation. Ford will not sell actuator separately - their solution is complete turbo replacement (€1,200-€1,500). However, turbo specialists can repair actuator alone for €500-€700. Some owners report success by replacing boost control valve (€150-€200 part, 2 hours labor). Prevention: use premium diesel, avoid constant gentle driving, perform Italian tune-up monthly (drive at 3,000+ RPM for 10-15 minutes to burn carbon). Check actuator movement reaches full travel at both ends. If caught early when actuator is merely sticky (not seized), cleaning may resolve issue.
Injector failure€400 - €1,800
Rough running, misfires, diesel leaks from engine · more· less
Injector problems most common on 2008-2009 models due to a faulty batch, but can occur on any year. Symptoms include engine juddering, running on less than all cylinders, limp mode activation, and visible diesel leaks around injector area. Important: often the high-pressure fuel pump breaks down internally and spreads metal flakes through the system, contaminating all injectors. Check fuel filter for "sparkly bits" - if present, pump must be replaced (€450) plus all injectors. If no metal contamination, perform overflow test to identify which injectors are failing. New OEM injectors cost €150-€200 each. Remanufactured injectors with 24-month warranty cost €100-€130 each. Always use diesel specialist - this is not a DIY job. Total repair including diagnosis and labor: €600-€1,800 depending on how many injectors need replacement.
EGR valve blockage€250 - €1,400
Rough idling, stalling, increased fuel consumption · more· less
EGR valve becomes clogged with soot over time, causing rough idling, erratic engine function, stalling, increased fuel consumption and emissions. Located at rear of engine making access difficult. Cleaning requires removing exhaust front pipe, turbo, and inlet manifold - book time is 2.8 hours but often takes longer. Professional EGR cleaning costs €250-€400 and should be done every 50,000 miles preventively. If valve is damaged or seized, complete EGR unit replacement costs €1,000-€1,400 at dealers (OEM parts €400-€500). Some owners choose to blank off EGR valve but this may cause emissions test failure and is illegal in many jurisdictions. EGR valves typically last 10 years or 150,000+ km with proper maintenance.
Power steering system failure€600 - €1,200
Heavy steering, fluid leaks, steering clunks and stiffness · more· less
Early S-Max models had known issues where debris from steering rack contaminates the system. Symptoms include steering stiffness when first turning right from straight-ahead, requiring significant force then suddenly going light causing jerky movements. The 2.0 TDCi uses electric power steering pump (versus belt-driven on 1.8). Common failures: power steering fluid leaks, electric pump failure, and rack contamination. If steering is sticky/heavy, first flush system with fresh fluid and replace reservoir (€150-€250). If fault persists, rack replacement needed (€1,000-€1,200 at Ford dealers, €600-€800 for reconditioned unit). Must also replace reservoir, pipes and pump simultaneously or debris will contaminate new rack. Ford may contribute to repair costs on early models as this was a known issue - contact Ford customer relations before paying for repairs.
Dead battery after 2-3 days parked, warning lights · more· less
Very common S-Max issue where battery drains completely within 2-4 days if car not used. Most frequent causes: faulty Bluetooth module in entertainment system (multiple owners report this exact issue), corroded regulator from water ingress, faulty door switches keeping dome lights on, and aftermarket alarm systems. Normal parasitic draw should be around 0.1A after 5-10 minutes - anything higher indicates a problem. Diagnosis: use multimeter between negative terminal and cable, then pull fuses one by one to identify circuit. Common fixes: remove Bluetooth module fuse (€0), replace entertainment head unit (€200-€400), or repair/replace corroded regulator (€150-€300). One owner's auto electrician said it was his second S-Max in two weeks with this exact problem. Quick test: disconnect negative cable when parking - if it starts fine when reconnected, you have parasitic drain, not bad battery.
Glow plug failure and seizure€300 - €1,700
Hard starting in cold weather, white smoke, rough idle · more· less
Glow plugs typically last 100,000+ km but carbon buildup reduces lifespan. Symptoms: difficulty starting especially in cold weather (takes longer than 3-5 seconds), white smoke at startup, rough idling until engine warms up, and check engine light with glow plug codes. On 2.0 TDCi, glow plug replacement is labor-intensive taking 3-5 hours due to accessibility. Ford quoted one owner €325 for replacement but warned of potential €1,700 repair if plugs break during removal - seized glow plugs can snap off leaving the tip in cylinder head requiring engine disassembly. Specialists use special extraction tools and penetrating oil. Replacement cost at Ford: €325-€500 if successful, up to €1,700 if extraction required. Independent diesel specialists charge €250-€400 for straightforward replacement. Each cylinder has one plug - even a single failed plug affects starting ability.
Rear parking sensors malfunction€30 - €150
Intermittent sensor faults, system shuts down completely · more· less
Very common S-Max issue caused by corroded rear parking aid wiring loom. The parking switch typically flashes three times indicating fault then shuts down entire system. The rear wiring harness (connecting all sensors) corrodes from moisture - especially common where multi-plug connector sits under driver's side bumper. Look for blue/green corrosion on wiring. New rear loom costs only €25-€35 and takes 10 minutes to replace at rear bumper. Some owners successfully strip and repair corroded sections but replacement recommended as new looms have improved sealing. Other potential causes: sensors themselves corrode with paint bubbles (€40-€60 per sensor), water intrusion in boot/spare tire bay, or faulty PAM module (€80-€150 used). This is a straightforward DIY fix - the wiring loom replacement is one of the easiest S-Max repairs.
Suspension wear (bushings, joints)€300 - €700
Clunking noises, uneven tire wear, poor handling · more· less
Common wear items on S-Max include anti-roll bar bushings (front most common), control arm bushings, and ball joints. Symptoms: clunking sounds over bumps, uneven tire wear especially on inside edges, wandering handling, and failed MOT/TÜV inspection. Anti-roll bar bushes cost €40-€80 per side plus 1-2 hours labor. Complete front suspension refresh including control arms, bushings, and ball joints costs €500-€800 at independent garages. The S-Max is heavy (1,700-1,800 kg) causing accelerated suspension wear especially on poor roads. Rear suspension toe links had a recall (2015-2020 models) for corrosion causing bolt failure. High-mileage vehicles (120,000+ km) commonly need suspension work. Regular inspection recommended - worn suspension degrades braking performance and safety. Budget €300-€400 for bushings, €500-€700 for comprehensive refresh.
Typical diesel MPV issues - not unreliable but requires proactive maintenance
The S-Max 2.0 TDCi exhibits typical modern diesel problems: DPF regeneration, DMF wear, and turbo issues. Owner experiences vary widely - some report 180,000+ km with minimal issues, while others face recurring problems. The engine itself is reasonably robust (PSA-Ford joint development) with proper maintenance. Main advice: avoid if you only do short trips (DPF will block), budget for DMF replacement at 100,000-120,000 km, and address timing chain rattle immediately if it appears. Manual gearbox versions are significantly more reliable than Powershift automatics. Parts availability is excellent and independent specialists can service these affordably.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete service records essential. Verify oil changes at 12,500 km intervals or annually. Check for DPF regenerations and timing chain inspection.
Tires
S-Max is heavy on tires due to weight. Use heavy-duty tires or inner sidewalls disintegrate. Check tread depth and uneven wear indicating suspension issues.
Cold start
Must start engine completely cold. Listen carefully for timing chain rattle in first 30 seconds. Any persistent rattle is serious.
Body condition
Check for rust, accident damage. Inspect interior trim fit - centre console and door trims break easily.
Test drive
Minimum 30 minutes including highway speeds. Monitor for DPF regeneration attempts, turbo response, and gearbox operation.
Specific for this vehicle
Cold start timing chain rattle test
This is the single most important check. Start engine stone cold and listen intently for first 30 seconds. Any rattle lasting more than 2-3 seconds indicates stretched chain needing €1,000-€2,200 replacement. Walk away if persistent rattling present.
Check for DPF warning lights and regeneration
Drive car for 20+ minutes. Watch for DPF warning light. Check oil level - if significantly over MAX mark, diesel has diluted oil from failed regenerations. Smell oil dipstick for diesel odor.
Test clutch pedal feel for DMF vibration
With engine running, hold clutch pedal - feel for vibrations pulsing through pedal. Listen for metallic rattling at idle that disappears when clutch depressed. These indicate DMF wear.
Verify turbo boost response and EPC light
Accelerate hard in 3rd gear from 1,500 RPM. Should pull strongly with no hesitation. Watch for EPC warning light indicating turbo actuator issues. Blue smoke on acceleration means turbo bearing failure.
Test power steering for stiffness and clunks
Turn steering wheel from straight to full right lock at low speed. Should be smooth without sudden stiff spots or clunking. Sticky steering especially going right indicates steering rack contamination issue.
Battery drain test
Ask seller how long car sits between uses. If battery drains within 2-4 days, parasitic electrical draw present. Check if Bluetooth/entertainment system has been replaced - this is common fix.
Check rear parking sensors and wiring
Test parking sensors. Look under driver's side rear bumper at multi-plug connector for green/blue corrosion. Very common issue but cheap to fix (€30 wiring loom).
Inspect for diesel leaks around injectors
Open hood and look at injector area on top of engine. Check for diesel wetness or staining. Diesel leak indicates injector seal failure requiring replacement.
Verify recall work completed
Use VIN to check Ford recall database. Key recalls: fuel leak (2012-2013), glass roof detachment (multiple), brake pedal issues, engine overheating/oil leak (2014-2015).
Check fuel filter for metal contamination
If possible, inspect fuel filter for metallic sparkly bits. These indicate high-pressure fuel pump breakdown contaminating entire fuel system - very expensive repair.
Gearbox type verification (avoid Powershift if possible)
Verify if manual or Powershift automatic. Manual is significantly more reliable. If Powershift, verify service history showing gearbox oil changes at 37,500 km intervals (€380-€450 each time).
Recalls and Technical Service Bulletins
Injector O-ring fuel leak (Dec 2012 - Feb 2013)Verify completed
Hard brake pedal during warm-up (Nov 2008 - Mar 2009)Verify completed
Rear suspension toe link corrosion (2015-2020 models)Verify completed
Heated windscreen earth point (various dates)Verify completed
There have been six major recalls for the S-Max covering fuel leaks, glass roof panels, and braking issues. Use your VIN on Ford's official recall lookup page to verify all recalls completed. Parts and service for recall repairs are free through Ford dealers.
Warranty Status
Factory warranty (3 years / 100,000 km)Expired on all 2006-2015 models
Anti-corrosion warranty (12 years)Check specific vehicle build date
All S-Max Mk1 models (2006-2015) are now outside their original factory warranty period. Extended warranties may be available through third-party providers but typically exclude common S-Max issues like DPF, DMF, and turbo problems. Anti-corrosion warranty may still apply on newer 2015 models - check with Ford using VIN.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.