Ford Galaxy / Ford S-MAX. Manual — part 438

Installation

Torque:

24 Nm

1. To install, reverse the removal procedure.

2. Using the diagnostic tool, select:

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

General Equipment:

Ford approved diagnostic tool

Engine Emission Control - 1.8L Duratorq-
TDCi (74kW/100PS) - Lynx/1.8L Duratorq-
TDCi (92kW/125PS) - Lynx - Exhaust Gas
Recirculation (EGR) Cooler

S-MAX/Galaxy 2006.5 (02/2006

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Removal and Installation

General Equipment

Removal

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

Hose clamp remover/installer

1.

2.

1. Torque:

22 Nm

3. Detach

the A
pillar
exterior
trim
panel
lower
clips.

3.

2. Torque:

10 Nm

4.

Installation

5.

CAUTION: Make sure that the inside of the

pipe ends are clean and free of oil residue.
NOTE: Make a note of the orientation of the
charger air cooler clamp.

6.

NOTE: The gaskets are to be reused unless
damaged.

General Equipment:

Hose clamp remover/installer

1.

NOTE: Only tighten the nut and bolts finger tight at
this stage.

2.

1. Torque: 23 Nm
2. Torque: 10 Nm
3. Torque: 10 Nm
4. Torque: 4 Nm

3. To install, reverse the removal procedure.

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 - Engine
Emission Control

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

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Description and Operation

Description

Exhaust gas recirculation (EGR) valve outlet tube

Exhaust manifold to EGR cooler tube

EGR cooler

EGR valve

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).

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