Ford Galaxy / Ford S-MAX. Manual — part 435

Engine Emission Control - 2.0L Duratec-
HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4 -
Engine Emission Control

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

Print

Diagnosis and Testing

General Equipment

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step.

4. 4. If the concern is not visually evident, verify the symptom and refer to the

Symptom Chart.

Symptom Chart

Worldwide Diagnostic System (WDS)

Mechanical

Electrical

Hose(s)/hose joints
Gasket(s)
Positive crankcase ventilation (PCV) valve
PCV separator
Exhaust gas recirculation (EGR) valve

Electrical connector(s)
Wiring harness
Fuse(s)
Relay
EGR valve
Powertain control module (PCM)

Symptom

Possible Sources

Action

Poor engine
performance

EGR valve.

*

Using the WDS, CHECK the EGR Valve Duty Cycle input

signal to the EGR vacuum regulator valve. If the result is
0%, REMOVE the EGR valve.
REFER to:

Exhaust Gas Recirculation (EGR) Valve

(303-

08A Engine Emission Control - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE (118kW/160PS) -
MI4, Removal and Installation).
INSPECT the EGR valve and valve seat for damage. Make
sure that the EGR valve is in the closed position. If the
EGR valve is not closed. INSTALL a new EGR valve. TEST
the system for normal operation. If the result is not 0%
continue the engine diagnostic using the WDS.

*

Excessive
crankcase
pressure

Blocked or

damaged PCV
hose(s).

Blocked

crankcase vent
oil separator.

*

*

CHECK the PCV system components for blockages, CLEAN

or INSTALL new components as necessary.

*

Worn or

damaged
engine
components.

*

REFER to: Engine (303-01A, Diagnosis and Testing).

*

Engine Emission Control - 2.0L Duratec-
HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4 -
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

Hose clamp remover/installer

1. Drain the cooling system.

Refer to:

Cooling System Draining, Filling and

Bleeding

(303-03A Engine Cooling - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-
HE (118kW/160PS) - MI4, General Procedures).

2.

3.

4.

NOTE: The gasket is to be reused unless
damaged.

General Equipment:

Hose clamp

remover/installer

Torque:

25 Nm

1.

CAUTION: Make sure that the mating

faces are clean and free of foreign material.

To install, reverse the removal procedure.

Engine Emission Control - 2.5L Duratec
(162kW/220PS) - VI5 - Engine Emission
Control

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

Print

Description and Operation

2.5L Duratec-ST (VI5)

Engine Emission Components

Description

Intake manifold to turbocharger breather hose

Crankcase vent oil separator to valve cover hose

Crankcase vent oil separator to intake manifold hose

Crankcase vent oil separator

Item

1

2

3

4

Part Number

-

-

-

-

Engine Emission Control - 2.5L Duratec
(162kW/220PS) - VI5 - Engine Emission
Control

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

Print

Diagnosis and Testing

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step.

4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom

Chart.

Symptom Chart

Mechanical

Electrical

Hose(s)/hose joints
Gasket(s)
Positive crankcase ventilation (PCV) valve
PCV crankcase vent oil separator
Turbocharger

Electrical connector(s)
Wiring harness
Fuse(s)
Relay
Powertain control module (PCM)

Symptom

Possible Sources

Action

Excessive
crankcase
pressure

Blocked PCV crankcase

vent oil separator.

Blocked PCV hose.

*

*

CLEAN or INSTALL new PCV components as

necessary. TEST the system for normal
operation.

*

Worn or damaged

engine components.

*

REFER to: Engine (303-01B, Diagnosis and

Testing).

*

Oil in the air
intake system

Crankcase vent oil

separator.

*

CLEAN or INSTALL a new crankcase vent oil

separator. TEST the system for normal
operation.

*

Turbocharger

*

REFER to: Turbocharger (303-04E, Diagnosis

and Testing).

*

Worn or damaged

engine components.

*

REFER to: Engine (303-01B, Diagnosis and

Testing).

*