Ford Galaxy / Ford S-MAX. Manual — part 436

Engine Emission Control - 1.8L Duratorq-
TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx -
Engine Emission Control

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

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Description and Operation

Description

EGR valve

EGR cooler to intake manifold gasket

EGR cooler

Exhaust manifold to EGR cooler tube gasket

The EGR system allows a measured quantity of exhaust gas to be directed back to the
intake manifold. The exhaust gas is introduced to the incoming charge air in the intake
manifold, where it mixes with the air/fuel mixture and lowers the peak gas temperature,
reducing nitrogen oxide (NOx) exhaust emissions. The EGR valve is electrically operated
and is controlled through an input from the powertrain control module (PCM).

The EGR system is fitted with an EGR cooler. The EGR cooler reduces the temperature of
the exhaust gasses being returned to the intake system. By reducing the EGR temperature,
the intake air charge density is not adversely affected, so maintaining the optimum fueling
characteristics.

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Description

Valve cover and crankcase to positive crankcase ventilation (PCV)
separator PCV hose

PCV separator to valve cover PCV hose

PCV separator

PCV separator to crankcase PCV hose

Description

PCV valve cover

PCV valve diaphragm

PCV valve bush

Valve cover

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Valve cover to air intake pipe PCV hose

PCV valve spring

The PCV system consists of an oil separator chamber connected to the crankcase and valve
cover by hoses.

The crankcase pressure is controlled by a diaphragm operated PCV valve built into the valve
cover. As the pressure in the oil separator reduces, the diaphragm valve closes against the
force of the PCV valve spring, so closing the PCV valve. As the crankcase pressure rises, the
PCV valve is pushed open assisted by the PCV valve spring. This allows the positive
crankcase gasses to be scavenged by the air intake system.

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Engine Emission Control - 1.8L Duratorq-
TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx -
Engine Emission Control—

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

Print

Diagnosis and Testing

General Equipment

Principles of Operation

Exhaust Gas Recirculation (EGR) system

To maintain the standards of low exhaust emission levels required of today's engines, the
EGR system on this engine is fully electronically controlled.

The EGR valve is a proportional electric motor controlled directly by a duty-cycle signal
from the powertrain control module (PCM). Integrated into the EGR valve is a valve position
sensor. The signal from the EGR valve position sensor allows for the precise control of the
timing and the quantity of exhaust gas to be recirculated. If the EGR valve becomes
inoperative or fails to close completely, the PCM will raise a diagnostic trouble code (DTC)
and the instrument cluster malfunction indicator lamp (MIL) will be illuminated.

If a new EGR valve is installed. The base setting (closed position) value must be configured
to the PCM. This is initiated using WDS. If the base setting is not configured to the PCM, the
setting from the previous EGR valve will be used and the control function of the EGR
system will be incorrect.

The EGR system is fitted with an EGR cooler. The EGR cooler reduces the temperature of
the exhaust gasses being returned to the intake system. By reducing the EGR temperature,
the intake air charge density is not adversely affected, so maintaining the optimum fueling
characteristics.

Positive Crankcase Ventilation (PCV) system

Description

PCV valve cover

Worldwide Diagnostic System (WDS) (418-
F224)

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