Ford Galaxy / Ford S-MAX. Manual — part 440

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

(303-01F Engine - 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

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

Intake Manifold

(303-01F Engine - 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, Removal and Installation).
TEST the system for normal operation.

Engine Emission Control - 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 -
Exhaust Gas Recirculation (EGR) Valve

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

Print

Removal and Installation

General Equipment

Removal

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

Installation

Worldwide Diagnostic System (WDS)

1. Remove the EGR valve tube.

Refer to:

Exhaust Manifold to Exhaust Gas

Recirculation (EGR) Valve Tube

(303-08D Engine

Emission Control - 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, Removal and Installation).

2. Remove the air cleaner.

Refer to:

Air Cleaner

(303-12E Intake Air

Distribution and Filtering - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW/2.0L Duratorq-TDCi
(118kW/160PS) - DW, Emission Requirements:
Stage IV/Stage V, Removal and Installation).

3.

NOTE: The gasket is to be reused unless
damaged.

1. Torque: 10 Nm
2. Torque: 8 Nm
3. Torque: 5 Nm

1. To install, reverse the removal procedure.

2. Using the WDS,

TOOLBOX/POWERTRAIN/SERVICE
FUNCTIONS/RESET KAM, reset the EGR valve.

General Equipment:

Worldwide Diagnostic

System (WDS)

Engine Emission Control - 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 - 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

(303-03E Engine Cooling - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, General Procedures).

2.

1. Torque:

22 Nm

3. Detach

the A
pillar
exterior
trim
panel
lower
clips.

3.

2. Torque:

10 Nm

4. General Equipment:

Hose clamp remover/installer

Torque:

10 Nm

Installation

5.

NOTE: Note the orientation of the clamp to aid
installation.
NOTE: The gasket is to be reused unless damaged.

1. Discard the clamp.
2. Torque: 30 Nm
3. Torque: 10 Nm
4. Torque: 10 Nm

1.

NOTE: Make sure that a new clamp is installed.
NOTE: Make sure that the clamp is installed to the
same orientation as when removed.

To install, reverse the removal procedure.