Ford Galaxy / Ford S-MAX. Manual — part 439

Description

Intake manifold

PCV hose

Oil filler tube

EGR electronic vacuum regulating valve vacuum reservoir

Item

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Part Number

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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-)

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 todays 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. At the end
of each drive cycle the PCM drives the EGR valve to the fully open and fully closed positions
several times. This assists with cleaning the EGR valve.

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 diaphragm

PCV valve

The PCV system is made up of an oil separator chamber connected to the crankcase by a
hose. The oil separator chamber is an integral part of the engine intake manifold.

The crankcase pressure is controlled by a diaphragm operated PCV valve built into the oil
separator. 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,

Worldwide Diagnostic System (WDS) (418-
F224)

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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.

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 cause is not visually evident, verify the symptom and refer to the DTC Index

Chart.

5. 5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to

continue diagnosis.

Diagnostic Trouble Code (DTC) Index Chart

Symptom Chart

Pinpoint Tests

Mechanical

Electrical

Exhaust gas recirculation (EGR) valve

EGR tube

EGR cooler

EGR tube clamp

Gasket

PCV hose

PCV oil separator

Electrical connector

Wiring harness

DTC

Description

Possible

Source

Action

P1412

MIL illuminated

EGR valve

REFER to Excessive exhaust black smoke in

the Symptom Chart

P0404

MIL illuminated

EGR valve

REFER to Excessive exhaust black smoke in

the Symptom Chart

P1335 Powertrain warning indicator

illuminated

EGR valve

REFER to Excessive exhaust black smoke in

the Symptom Chart

Symptom

Possible

Sources

Action

Excessive
exhaust
black smoke

EGR valve.

*

Using the WDS, CHECK the PCM calibration. If necessary

UPDATE the PCM calibration to the latest level. Using the
WDS, TOOLBOX/POWERTRAIN/SERVICE FUNCTIONS/RESET
KAM, RESET the EGR valve. Carry out a road test, if the
concern persists GO to Pinpoint Test

A.

*

Excessive
crankcase
pressure

Blocked or

damaged PCV
hose(s).

Blocked PCV

oil separator.

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*

GO to Pinpoint Test

B.

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Worn or

damaged
engine
components.

*

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).

*

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 WDS.
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 WDS, 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

(303-08D 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).
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

(303-08D 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).

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

(303-08D 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).
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.

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