Ford Galaxy / Ford S-MAX. Manual — part 442

Pinpoint Tests

PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

A1: CHECK THE EXHAUST GAS RECIRCULATION VALVE POSITION

NOTE: Allow the engine to idle for a minimum of four minutes before carrying out the
system checks using the Ford approved diagnostic tool.
NOTE: After the engine is switched off, the EGR valve will attempt the cleaning cycle up
to a maximum of 18 times. If 18 cycles are seen during the test the EGR valve is suspect
and should be changed.

Ignition switch in position III.

1

Using the Ford approved diagnostic tool, DATALOGGER, set the parameters
DPFEGR, RPM, EGRDC#.

2

Set DATALOGGER to RECORD.

3

Ignition switch in position 0.

4

Does the DPFEGR 0 to 5 volt parameter change from a minimum approximate
value of 0.9 volts to a maximum approximate value of 4.2 volts for a total of 6
cycles?
Yes

GO to A2

.

No

RECORD the DTCs and DATALOGGER freeze frame data. INSTALL a new
EGR valve.
REFER to:

Exhaust Gas Recirculation (EGR) Valve

(303-08E Engine

Emission Control - 2.2L Duratorq-TDCi (129kW/175PS) - DW, Removal and
Installation).
TEST the system for normal operation.

A2: CHECK THE EXHAUST GAS RECIRCULATION VALVE FOR DAMAGE

Remove the EGR valve.
REFER to:

Exhaust Gas Recirculation (EGR) Valve

(303-08E Engine

Emission Control - 2.2L Duratorq-TDCi (129kW/175PS) - DW, Removal and
Installation).

1

INSPECT the EGR valve and valve seat for damage or excessive carbon
build up. REMOVE the plastic cover on the EGR valve and check the EGR

valve cam actuator for free movement.

2

Is the EGR valve undamaged and in the closed position and the EGR valve cam
actuator free to move?
Yes

To continue diagnostics,
REFER to:

Fuel Charging and Controls

(303-04E Fuel Charging and Controls

- 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Emission
Requirements: Stage IV, Diagnosis and Testing).

No

INSTALL a new EGR valve.
REFER to:

Exhaust Gas Recirculation (EGR) Valve

(303-08E Engine

Emission Control - 2.2L Duratorq-TDCi (129kW/175PS) - DW, Removal and
Installation).
TEST the system for normal operation.

PINPOINT TEST B : EXCESSIVE CRANKCASE PRESSURE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

B1: CHECK THE PCV HOSE FOR BLOCKAGE

Remove the PCV hose.

1

Inspect the PCV hose for blockage.

2

Is the PCV hose free from blockage?
Yes

GO to B2

.

No

CLEAN or INSTALL a new PCV hose as necessary.
TEST the system for normal operation.

B2: CHECK THE PCV VALVE FOR DAMAGE

Inspect the PCV valve for damage or blockage.

1

Is the PCV valve spring undamaged and the PCV valve
free from blockage?
Yes

TEST the system for normal operation. If the concern
persists,
REFER to:

Engine

(303-01G Engine - 2.2L Duratorq-

TDCi (129kW/175PS) - DW, Diagnosis and Testing).

No

CLEAN the crankcase vent oil separator and PCV
valve assembly or INSTALL a new intake manifold as
necessary.
REFER to:

Intake Manifold

(303-01G Engine - 2.2L

Duratorq-TDCi (129kW/175PS) - DW, Removal and
Installation).
TEST the system for normal operation.

Engine Emission Control - 2.2L Duratorq-
TDCi (129kW/175PS) - DW - Exhaust Gas
Recirculation (EGR) Valve

S-MAX/Galaxy 2006.5 (02/2006-)

Print

Removal and Installation

Removal

Installation

1. Refer to:

Exhaust Gas Recirculation (EGR) Cooler

(303-08E Engine Emission Control - 2.2L
Duratorq-TDCi (129kW/175PS) - DW, Removal
and Installation).

1. Refer to:

Exhaust Gas Recirculation (EGR) Cooler

(303-08E Engine Emission Control - 2.2L
Duratorq-TDCi (129kW/175PS) - DW, Removal
and Installation).

Engine Emission Control - 2.2L Duratorq-
TDCi (129kW/175PS) - DW - Exhaust Gas
Recirculation (EGR) Cooler

S-MAX/Galaxy 2006.5 (02/2006-)

Print

Removal and Installation

General Equipment

Removal

NOTE: Removal steps in this procedure may contain installation details.

Hose clamp remover/installer

1. Drain the cooling system.

Refer to:

Cooling System Draining, Filling and

Bleeding

(303-03D Engine Cooling - 1.8L

Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, General
Procedures).

2. General Equipment:

Hose clamp

remover/installer

3.

NOTE: Use new seals.

Torque:

1 10 Nm
2 10 Nm
3 8 Nm

4.

5. Torque: 10 Nm